Method of fabricating building wall panels

ABSTRACT

Methods of fabricating wall panels by generally continuously pultruding a wall panel profile comprising inner and outer layers, and spaced reinforcing webs and/or foam extending between the inner and outer layers, optionally studs extending inwardly from the inner layer, away from the outer layer. The so-continuously pultruded wall panel optionally has male and a female edges. The wall panel is periodically cut for wall panel height, thereby creating an ongoing stream of cut wall panels. The panels are advanced through a corner index station, and indexed at right angles while maintaining orientation of the panels. The wall panels leave the indexing station edge-to-edge. Resin is applied to facing edges of adjacent wall panels. Adjacent wall panels are joined to each other at the facing edges, to make a generally continuous wall panel. The so-joined wall panel is cut to desired lengths. The resulting wall panel can provide tough, water-proof, otherwise weather-proof, building systems and buildings, without structural use of concrete except in floor slabs.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a Non-Provisional of 61/008,379, filed Dec. 19,2007, this application is a Continuation-in-Part of application Ser. No.11/901,174 filed Sep. 13, 2007, this application is aContinuation-in-Part of application Ser. No. 11/901,057, filed Sep. 13,2007, this application is a Continuation-in-Part of application Ser. No.11/900,987, filed Sep. 13, 2007, this application is aContinuation-in-Part of application Ser. No. 11/900,998, filed Sep. 13,2007, this application is a Continuation-in-Part of application Ser. No.11/901,059, filed Sep. 13, 2007, this application is aContinuation-in-Part of application Ser. No. 11/901,173, filed Sep. 13,2007, this application is a Continuation-in-Part of application Ser. No.11/901,175, filed Sep. 13, 2007, this application is a Non-Provisionalof application Ser. No. 60/872,929, filed Dec. 4, 2006, this applicationis a Non-Provisional of 60/876,403, filed Dec. 21, 2006, thisapplication is a Non-Provisional of application Ser. No. 60/923,822,filed Apr. 16, 2007, each of the above being incorporated by referencein its entirety.

BACKGROUND OF THE INVENTION

This invention relates to building systems which largely replaceconcrete, whether ready-mix concrete or pre-fabricated concrete blocks,or other pre-fabricated concrete products, in construction projects. Ingeneral, the invention replaces the concrete in below-grade frost wallsand foundation walls, in above-grade walls and in concrete footers, andin post pads. Such concrete structures are replaced, in the invention,with pultruded structures, and structures otherwise fabricated, suchstructures being based on resin-impregnated, fiber-based layers, ascomposite materials, also known as fiber-reinforced polymer materials(FRP). Such structures typically include thermally insulating foam, andoptionally include regularly-spaced “studs”, especially in upright,below-grade wall sections. Thus, with the exception of concrete flatwork such as concrete floors, the conventional ready-mix concrete truckis not needed at the construction site.

In conventional foundation construction, first a concrete footer isformed and poured using ready-mix concrete. After the poured concretefooter has cured to a sufficient degree, such as a few days later,concrete forms, e.g. 4-8 feet (1.8-3.6 meters) high, are brought in,assembled on site, and erected on top of the footer. Ready-mix concreteis then poured, from a ready-mix truck, into the forms and allowed toset up and cure, to thus create the foundation walls, which may be afrost wall if no basement is planned.

In the alternative, and still addressing conventional foundationconstruction, the upright portion of the foundation wall can be builtusing pre-fabricated concrete masonry units (cmu's) and mortar,typically supported by conventional poured concrete footers.

In yet another conventional type construction, the frost walls orfoundation walls are built using mortared concrete blocks.

In any event, in such conventional structures, as the concrete is beingfinished at the tops of the forms, or at the top course of concreteblocks, bolts or other hold-down anchors are partially embedded in thesetting-up concrete or mortar such that the anchors extend from the topof the foundation wall and, once the poured concrete, or mortar, has setup, such anchors serve as hold-down anchors, for example to mount a topplate, also known as a mud sill, to the top of the foundation wall, thusto anchor the overlying building structure to the foundation or frostwall. Once the concrete in a conventionally-poured foundation wall setsup, the forms are removed, e.g. 1-2 days after the ready-mix concrete ispoured into the forms, and a wood, or wood-product, or other top plateis anchored to the top of the concrete foundation wall, using theanchors which are embedded in the concrete at the top of the concretefoundation wall. A similar waiting time is needed with a mortaredconcrete block wall, before the top plate is anchored to the top of theso fabricated wall.

The above-noted poured concrete wall construction process, and concreteblock construction process, both require a substantial quantity ofconcrete materials, investment in forms, substantial on-site labor andseveral days of time to fabricate the building foundation on which theground floor of the building can then be erected. If construction isdone in winter in a northern climate, the concrete is typically heated,incurring an associated cost, in order to facilitate curing of theconcrete.

In addition, a resulting such concrete foundation wall is permeable towater and so must be water-proofed though, even after a conventionalwater-proofing coating has been applied to make the foundation wallwater-proof, water leakage through such concrete foundation wall,whether ready-mix wall or concrete block wall, is rather common.Further, a concrete wall is a good heat conductor, and thus should beinsulated to avoid heat loss by conduction through the concrete to thesoil or other fill which surrounds the building. However, the affect ofsuch insulation is limited because only relatively thin insulationmaterials are commonly used with underground concrete wall construction.

Yet further, if the level of the building inside the concrete wall is tobe inhabited, whether below grade, e.g. foundation wall, or above grade,then stud furring e.g. 2×4 studs or 2×6 studs are typically attached tothe concrete wall as a substrate which facilitates installation ofinsulation and utilities, and serves as a substrate for installing afinished interior wall surface such as sheet rock or paneling. Suchfurring takes up interior space inside the building as well as costingadditional time and money to install.

The overall time required to construct such building foundation can bereduced by fabricating concrete walls off-site and erecting thefabricated walls in place on site, using a crane. However, each suchwall element must be custom-designed, adding to the cost; and relativelyheavy-duty mechanical lifting equipment, e.g. the crane, must be broughtto the construction site, also a cost item.

Getting foundation walls installed in a timely manner, to accommodatetimely delivery of constructed homes and other buildings to buyers, is asignificant issue in the construction business. There are many reasonswhy foundations are not installed in accord with a planned schedule. Asubstantial such problem is weather. The weather in northern climatescan be below freezing for several months of the year, which makes itdifficult to get foundations installed. In addition, installing qualityconcrete foundation walls requires skilled labor, as well as skilledsubcontractors, including the subcontractors' skilled labor.

Another known method of constructing structural walls is the use ofInsulated Concrete Form (ICF) walls. In such construction, insulatedforms are erected on footers, and receive ready-mix poured concrete.After curing, the outer portions of the forms are left as a layer ofthermal insulation between the concrete and at least one of the innerand outer surfaces of the resulting wall. Although ICF walls do offer arelatively higher level of thermal insulation than a conventionaluninsulated concrete wall, an ICF wall is typically more expensive thana plain concrete wall, and is more difficult to finish than a plainconcrete wall, whether finishing the insulated interior of the wall orthe insulated exterior of the wall.

Yet another alternative conventional foundation wall system isconstructed of wood which has been treated to inhibit decay, andcorresponding decomposition of the wood. Such treated wood is well knownand is conventionally available. Such foundation walls typically includeat least a bottom plate, and can be wrapped in plastic and then set onan aggregate stone footer. Wood foundations have a number of advantages,including enabling a manufacturer of such wood foundations to fabricatesections of such wall in the closed and controlled environment of amanufacturing facility, whereby selling and delivering such product isgenerally insensitive to weather conditions. Further, wood offersbeneficial speed in constructing a building, and is relatively lightweight compared to concrete.

However, wood foundations are not well received by the consuming public,as the public does not perceive quality in a building where wood is usedin a below-grade application.

There is a need, in the construction industry, for relatively lightweight structural building panels, for example generally continuous wallpanels of any desired length up to a maximum length per panel,selectable in length, in height, and in thickness, which structuralbuilding panels can be used in applications where concrete isconventionally used in residential, light commercial, and lightindustrial construction, and which structural building panels are strongenough to bear both the compressive loads and the lateral loads whichare typically imposed on concrete walls in such building structures.

There is also a need for walls which have superior moisture and waterbarrier properties.

There is yet further a need for walls which can be installed so as to beready to support overlying building structure in a relatively shorterperiod of time.

There is still further a need for walls which can be installed at alower life cycle cost.

There is further a need for accessories which support other structurewhich bears on such wall sections, and which serve as connectors betweensuch wall sections and such other structure.

There is also a need for such walls which meet consumer expectations,both as to function and as to perception of quality.

These and other needs are alleviated, or at least attenuated, by thenovel construction products and methods of the invention.

SUMMARY OF THE INVENTION

This invention represents wall panels, and methods of making wall panelsfor a tough, water-proof building system which provides wall, ceiling,and/or floor building panels and corresponding walls and wall sections,ceilings and ceiling sections, and floors and floor sections. The walls,taken in a vertical orientation, have both verticalcompression-resistance strength, and horizontal bending-resistancestrength, sufficient that the wall system can be used in bothabove-ground and below-ground building structural applications,including applications where such wall systems are exposed to severewind and other weather, such as hurricanes, tornadoes, and the like.Such walls can replace concrete, and can meet required strengthspecifications for use in corresponding single family residential, lightcommercial, and light industrial applications.

Similarly, ceilings and floors can be made with building panels of theinvention having vertical and horizontal loading capacities sufficientto support the loads typically imposed on corresponding ceilings andfloors in single family residential, light commercial, and lightindustrial construction.

A wall structure of the invention has an outer waterproof layer,comprised of reinforcing fibers embedded in polymeric resin, anddefining the outwardly-facing surface of the panel, an inner waterprooflayer comprised of reinforcing fibers embedded in polymeric resin anddefining the inwardly-facing surface of the panel, and at least one of(i) one or more structurally reinforcing webs, spaced from each other,and extending between the inner layer and the outer layer, and (ii) oneor more foam boards filling spaces between the inner and outer layers. Aplurality of fiber-reinforced polymeric structurally-reinforcing memberscan extend the full height of the erected wall panel, and can extendfrom locations at or proximate the inner surface of the outer layer tolocations at or proximate an inner surface of the wall structure, atspaced locations along the length of the wall panel.

The inner layer, the outer layer, and the reinforcing members are allpart of a fiber-reinforced, optionally pultruded, resinous structure.

Optionally, a reinforcing stud is attached to, or included in, thefabricated structure, and extends inwardly into the building beyond whatis otherwise the inner surface of the building panel/wall panel. Thestud can originate at either the inner layer or the outer layer of thepultruded structure.

The spaces between ones of the structurally reinforcing member, andbetween the inner and outer layers, are optionally filled with rigidinsulating foam material such as polyurethane foam or polystyrene foam,phenolic foam, or polyisocyanurate foam.

The structurally-reinforcing members may be integral with the inner andouter layers, whereby the reinforcing elements of thestructurally-reinforcing members, which extend between the inner andouter layers, function in a capacity similar to the web of an I-beam,and associated portions of the inner and outer layers, function incapacities similar to the functioning of flanges of such I-beam. Theoverall I-beam effect provides, in an upstanding wall panel, or wall,both horizontal bending resistance and vertical compressive strength,sufficient to support both the vertical compressive loads, and thelateral side loads, for which building walls are designed, and canprovide such sufficient levels of strength in cross-sections which areno greater than the cross-sections of steel reinforced concrete wallswhich are conventionally used in such applications, while avoiding thedrawbacks of concrete.

A foundation wall of the invention can be laid directly on a leveled bedof stone aggregate as a footer. Alternatively, foundation walls of theinvention can be laid on a poured concrete footer, with suitablegasketing between the concrete footer and a lower surface of thefoundation wall, to accommodate deviations in the top surface of suchconcrete footer. Still further, the footer can be elongate support padsmade with fiber-reinforced polymeric materials described herein for usein making the building panels of the invention.

The invention comprehends that when buildings and other structures areconstructed using the inventive structural elements and membersdisclosed herein, such buildings, and other structures, themselves, aswell as respective substructures and subassemblies which are related tosuch buildings and structures, are inventive.

The invention generally comprises building panels, and methods offabricating building panels as either defined-length panels anddefined-height panels, in controlled-environment manufacturingfacilities. Taken in an upright orientation, such building panel has adefined length, a defined thickness, and a defined height. Acontinuously-pultruded panel can be cut to any desired height along thelength of the pultruded product, and panels can be joined and/or cut toprovide any desired panel lengths, at the manufacturing facility. Thus,walls and wall panels can be delivered from the manufacturing facilityin a variety of lengths and/or heights. In addition, the panels can becut as needed at the construction site such as to create rough openingsfor windows and/or doors.

An exemplary method for manufacturing such building panels comprisescontinuously pultruding panels having defined default panel lengths andthicknesses, cutting the panels at desired panel heights, and joiningadjacent panels at panel edges and/or cutting panels or panel assembliesto achieve desired panel lengths. Thermally-insulating foam can beincorporated into the pultruded structure, either during fabrication ofthe pultrusion product, or after the pultrusion product has been cured,dimensionally set.

The panels can be formed with or without studs which extend, from theinner layer, away from the outer layer. A stud leg can be aligned withone of the structurally reinforcing members. Under load of an overlyingbuilding, panels with studs deflect outwardly of the building toward thesoil backfill. When installed on a fabricated footer, a panel of theinvention can vary in height by a factor of no more than 0.25 inch (6.4mm) over a 40 foot (12.7 m) distance. In a 9 foot (2.7 m) high wall,load distribution at the footer varies by no more than 25% over any 10foot (3.05 m) length of a foundation wall of the invention.

For example, pre-fabricated foam blocks can be fed into the pultrusionprocess along with resin and reinforcing fiber. The foam blocks may bepre-wrapped with fiberglass, or the foam blocks and fiber can be fedseparately to the pultrusion process.

The invention still further comprehends methods of constructingbuildings, comprising constructing a building or building appurtenance,the method comprising excavating a hole to establish a natural base onwhich the structure is to be supported and constructed; establishinglayout locations where upright walls or other supports of the structureare to be erected; establishing a fabricated footer, optionally apultruded fiber-reinforced polymeric footer, along the laid-outlocations of the supports; placing pre-fabricated load-bearing pultrudedbuilding panels or other supports on the fabricated footer; connectingthe pre-fabricated wall panels or other supports to each other if and asdesired thereby developing load-bearing walls or other supports; anderecting overlying structure on the load-bearing walls or othersupports.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a representative pictorial view, with parts removed, of abuilding foundation wall fabricated using building system structures ofthe invention.

FIG. 2 is a fragmented interior view of a section of one of theupstanding wall structures shown in FIG. 1.

FIG. 3 is an elevation-view cross-section of the upstanding wallstructure taken at 3-3 of FIG. 1.

FIG. 4 is an outside elevation representation of the upstanding wallstructure of FIG. 3.

FIG. 5 is a plan-view cross-section of a portion of a foundation wall,below any brick ledge, according to a second embodiment of theinvention, with studs, and with a layer of sheet rock attached over thestuds, and viewing the base plate between the sheet rock and a main runsection of the panel.

FIG. 5A is a glass schedule cross-section, showing glass uses in anexemplary portion of a wall panel of the invention.

FIG. 6 is an elevation view cross-section of the foundation wallstructure illustrated in FIG. 5, showing a brick ledge.

FIG. 6A is an elevation view cross-section as in FIG. 6, without thebrick ledge, illustrating a different arrangement for supporting theoverlying floor.

FIG. 6B is an enlarged view of a top portion of the structure shown inFIG. 6A.

FIG. 6C shows an enlarged elevation view of a top portion of analternative wall section, showing anchoring of the overlying buildingstructure to the underlying wall structure.

FIG. 6D is a representative elevation view, similar to FIG. 6, showingtypical relative lateral soil loading on a wall.

FIG. 6E is a chart showing typical relative lateral loading for threewall heights, each for three soil types, generally showing lateralforce, loading information in table format.

FIG. 7 is a fragmentary pictorial view showing a basement support pad ofthe invention, supporting a conventional support post which supports anI-beam as in a below-grade basement location.

FIG. 8A is a cross-section of a layered support pad illustrated in FIG.7, shown on an underlying rock or earth support base.

FIG. 8B is a cross-section of a pultruded support pad illustrated inFIG. 7, shown on an underlying rock or earth support base.

FIG. 9 is a pictorial view of a square resin-fiber composite supportpost, and resin-fiber composite cap, of the invention, supported by asquare resin-fiber composite support pad of the invention.

FIG. 10 is a pictorial view of a square resin-fiber composite supportpost, and resin-fiber composite cap, of the invention, supported by asquare resin-fiber composite, upwardly-tapered support pad of theinvention.

FIG. 11 is a pictorial view of a round resin-fiber composite supportpost, and resin-fiber composite cap, of the invention, supported by acircular resin-fiber composite support pad of the invention.

FIG. 12 is a pictorial view of a round resin-fiber composite supportpost, and resin-fiber composite cap, of the invention, supported by acircular, upwardly-tapered resin-fiber composite support pad of theinvention.

FIG. 13 is a pictorial line rendering of an optionally pultrudedresin-fiber composite support bracket of the invention, which may bemounted on the top of a foundation wall of the invention as illustratedin FIG. 6.

FIG. 13A is a pictorial line rendering of a resin-fiber composite “H”connector of the invention, which can be used to connect first andsecond wall panels in a straight line.

FIGS. 14 and 14A are line drawing pictorial views of resin-fibercomposite plate anchor brackets useful proximate the tops and bottoms ofwall panels of the invention e.g. for anchoring a top plate and/or abottom plate to the wall panel, and for transferring lateral loads tothe overlying floor.

FIG. 14B is a line drawing pictorial view of an alternative resin-fibercomposite angle bracket which can be used in place of brackets 14 and14A.

FIG. 15 is a pictorial line rendering of a resin-fiber composite floorand garage apron ledge bracket of the invention.

FIG. 15A is a plan view cross-section of a joint in a wall of theinvention, joining first and second building panels of the inventionusing an “H” connector of FIG. 13A.

FIG. 16 shows a wall section illustrating plan view cross-sections offragmentary portions of first and second upstanding building panels,illustrating a first set of edge structures in the two panels.

FIG. 17 shows a wall section illustrating plan view cross-sections offirst and second upstanding building panels joined to each other inend-to-end relationship at the panel edges, including integral studs inthe panels, and sheet rock being applied over the studs.

FIGS. 18 and 19 show plan view cross-sections of pultruded hollow panelsand foam-filled panels of the invention.

FIG. 20 is a representative plan view of an exemplary pultrusion andassembly process of the invention by which wall panels and wall sectionscan be fabricated to essentially any wall height and any wall length.

FIG. 21 is a representative plan view cross-section of a wall paneldevoid of the structurally-reinforcing members between the inner andouter walls, wherein foam blocks pre-wrapped with fiberglass areassembled to a pre-fabricated panel.

FIG. 22 is a representative plan view cross-section of a wall panelhaving studs but no structurally-reinforcing members.

FIG. 23 is a representative plan view cross-section as in FIG. 22 butwith upwardly-oriented T-shaped reinforcements.

FIG. 24 is an elevation view, from outside a building, of a section of awall, generically illustrating relative load distribution for anexemplary concrete wall section, and for a corresponding exemplary wallsection of the invention.

The invention is not limited in its application to the details ofconstruction, or to the arrangement of the components set forth in thefollowing description or illustrated in the drawings. The invention iscapable of other embodiments or of being practiced or carried out invarious other ways. Also, it is to be understood that the terminologyand phraseology employed herein is for purpose of description andillustration and should not be regarded as limiting. Like referencenumerals are used to indicate like components.

DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

Referring to FIG. 1, a plurality of interior and exterior foundationwalls 10 collectively define the foundation 12 of a building. Eachfoundation wall 10 is defined by one or more foundation wall panels 14.In the illustration, each foundation wall panel 14 includes a bottomplate 16, an upstanding wall section 18, and a top plate/mud sill 20. Asused herein, “wall panel” 14 may refer to wall section 18 without topplate 20 or bottom plate 16. Each upstanding wall section 18 includes amain-run wall section 22, and uprightly-oriented reinforcing studs 23affixed to, or integral with, the main-run wall section, regularlyspaced along the length of the wall section, and extending inwardly ofthe inner surface of the main run wall section. In the embodimentillustrated in FIG. 1, anchoring brackets 24 are mounted to the studs atthe tops and bottoms of the wall section, thus to assist in anchoringthe bottom plate and the top plate, and/or any other attachment, to themain run portion of the upstanding wall section.

A given stud 23 (FIGS. 1-2 and 4-5) or 123 (FIGS. 3, 6, 6A, 6B, and 17)has an end panel 130, and side panels 128 which extend from the main runportion of the wall panel to end panel 130.

As illustrated in FIG. 1, conventional e.g. steel I-beams 26 are mountedto the wall sections, as needed, to support spans of overlying floors.Such steel I-beam can be supported at one or more locations along thespan of the I-beam, as needed, by either conventional e.g. steel posts,or by resin-fiber composite posts 28 of the invention (FIGS. 1 and 8-12)and/or resin-fiber composite pads 30 (FIGS. 1 and 8-12) of theinvention. Additional support posts can be employed at or adjacent theends of the I-beams as needed to satisfy specific, individualload-bearing requirements of the building design. Fiberglass-reinforcedbrackets, or reinforcing studs 123 (FIGS. 3 and 5) or conventional e.g.steel brackets, can be used to attach and/or support the I-beamsrelative to respective panels of the foundation wall using e.g.conventional steel bolts. Studs 23, are cut off, as needed, to supportthe I-beam at the desired height. Multiple studs can be usedside-by-side, as needed, to provide the desired load-bearing capacity.In the alternative, beam pockets can be fabricated in the foundationwall to receive the ends of the I-beam.

Referring now to FIGS. 3 and 5, the main run portion 22 of the wallsection is generally defined between the inner surface 25 and the outersurface 56 of the wall panel, without considering the thicknesscontribution of stud 23 to the wall panel. The main run portion of thewall section can be a pultruded structural profile, which optionallyincludes thermally insulating foam in pultrusion cavities. The foam canbe foamed in place thermally insulating material in the pultrusioncavities. Alternatively, the foam can be fed as foam blocks into thepultrusion process such that the pultruded resin/fiberglass compositionforms about the foam blocks. Bottom plate 16 and top plate 20 can besecured to the main run portion of the wall section with the support ofwedge-shaped brackets 24 (FIGS. 2, 14, and 14A), or other supportingbracket structure, optionally in combination with adhesive or additionalcurable polymeric resin. The selection of adhesive depends on theselection of the material from which the top plate is made, as well asthe specific material which forms the respective wall sectionpultrusion, and the material from which bracket 24 is made. An exemplaryadhesive is Pro-Series QB-300 Multi-Purpose Adhesive, available from OSISealant Company, Mentor, Ohio. Such adhesive can be used as desired tosecure various elements of the building panel assembly to each other.

The foam material in the wall panel cavities is of sufficient density,rigidity, and polymer selection to provide the desired level of thermalinsulation between the inwardly-facing surface of the wall and theoutwardly-facing surface of the wall.

Bottom plate 16 can be a fiber-reinforced, e.g. fiberglass-reinforced,polymeric structural member, of such dimensions and structure as to besufficiently rigid, and with sufficient strength, to support both thefoundation wall and the overlying building superstructure, from anunderlying fabricated base defined by e.g. a settled bed 53 (FIG. 6) ofstone aggregate, from an underlying fabricated base comprising aconcrete footer 55 (FIG. 3), or from other suitable underlyingfabricated supporting base. The specific structural requirements ofbottom plate 16 can be engineered based on the loads to be applied tothe wall which is supported by the supporting base.

A pultruded fiber-reinforced product e.g. 0.075 inch (1.9 mm) to about0.5 inch (13 mm) thick has been found to be satisfactory as the bottomplate for general-purpose and typical single-family residential, lightcommercial, and light industrial construction.

The bottom plate can be attached to the upstanding wall section, andoptional support brackets 24 by adhesive, by curable resin such as thatused in the wall panel, by steel bolts which extend through an uprightleg of the bottom plate e.g. adjacent the outer surface of theupstanding wall section and through the adjacent portion of theupstanding wall section, or by a combination of metal anchors andadhesive and/or resin or by other attachment mechanism. In any event,the bottom plate, when attached to the upstanding wall section, issufficiently wide, thick, dense, and rigid, to provide effectivecompression and bending support, thus to support the foundation wallfrom the underlying soil and/or rock and/or stone, or other natural basealbeit typically through a fabricated footing.

The bottom plate typically extends laterally inwardly into the buildingbeyond the primary surface of the inner layer by a distancecorresponding to at least the maximum thickness of the building panelwhich includes stud 123, thus to present a suitably-sized bearingsurface to the underlying support base/footer whereby the overlying loadcan be borne by the underlying footer without causing substantialvertical or lateral movement in the underlying natural support base ofsoil, stone, or rock. In the alternative, the bottom plate can extendoutwardly from the building panel, away from the building, to providethe recited suitably-sized bearing surface, or can extend both inwardlyand outwardly from the building panel.

The top plate can be made of wrapped layers of fiberglass, can be apultruded resin-fiber composite, can be conventional wood, or amanufactured wood product, or other conventional construction material,each such structure being sufficiently wide and thick to provide asupport surface, interfacing with the underlying upstanding wallsection, and from which the overlying superstructure of the building canbe supported. The top plate can conveniently be made from conventionalwood building materials whereby overlying building structures can beconventionally attached to the underlying foundation wall structure atthe building site by use of conventional fasteners, conventionallyattached to the top plate.

The combination of the inner and outer layers 34, 36 of the wall panel,and the reinforcing studs 123, is sufficiently strong to withstand theinwardly-directed lateral, e.g. bending, forces which are imposed on afoundation wall by the ground, or on above-ground walls by wind loads,both imposed from outside the building.

A suitable illustrative footer can be fabricated from aggregate stone,illustrated as 53 in FIG. 6, or concrete as illustrated at 55 in FIG. 3.A suitable exemplary aggregate stone has a size which passes through a 1inch mesh and does not pass through a ¾ inch (1.9 cm) mesh.

Referring to FIGS. 1, 3, and 6, once the foundation wall 10 is in placeas illustrated in FIG. 1, on a suitable footer (53, 55), a conventionalready-mix concrete slab floor 38 is poured. The concrete slab floorextends over, and thus overlies, that portion of the bottom plate 16which extends inwardly from any of the inner surfaces of the wallpanels, including both the main run wall section and studs 23. Namely,the concrete slab floor extends to, and abuts against, the innersurfaces of the respective upstanding wall sections 18. Accordingly,once the concrete slab floor is cured, inwardly-directed lateral forces,imposed by the ground outside the building, at the bottom of the wall,and taken in a direction aligned with the width of bottom plate 16, areresisted, opposed, nullified, by the structural e.g.lateral/side-to-side compressive strength of the concrete floor slab 38in support of foundation wall 10, as the edge of the slab abuts theinner surface of the foundation wall. Thus, inwardly-directed lateralforces which are imposed on the foundation wall adjacent bottom plate 16are ultimately resisted, and absorbed, by slab 38.

Inwardly-directed lateral forces which are imposed on the foundationwall at or adjacent top plate 20 can be transferred to main floor 40 ofthe building (FIGS. 3, 6, and 6A) e.g. by conventional mechanicalfasteners and standard construction techniques which mechanically attachthe main floor 40 and the foundation wall 10 to each other, or otherwisecause the main floor and the foundation to act together cooperatively.

Still referring to the main run wall section 22 (FIGS. 1, 3, and 5), andconsidering the structural environment of typical 1-story and 2-storyresidential construction, the inner 34 and outer 36 pultruded layers aree.g. between about 0.75 mm and about 12.7 mm (between about 0.03 inchand about 0.5 inch) thick. Thicknesses of the inner 34 and outer 36layers are generally constant. Outer layer 36 can be e.g. ribbed toenhance the ability of the wall to withstand the imposition oflaterally-directed loads on the wall without further increasing thelayer thickness.

In the embodiments illustrated in FIGS. 1-5, studs 123, where used, runthe full height of the main wall section, and extend from the innersurface 52 of the inner fiberglass layer 34, inwardly a desired distanceso as to provide the desired level of structural strength to wall panel14. Thus, studs 123 function as reinforcing members in wall panel 14.

Compared to e.g. a 2.0 inch (5.1 cm) thick wall section, 8 feet (2.4 m)in height, having no reinforcing member, a corresponding wall whichincorporates studs 123 on 16 inch (40.6 cm) centers, and extending about3.5 inches (about 8.9 cm) exhibits at least about 75% increased bendingresistance. Such bending resistance is measured by applying a linearload which runs the length of the wall panel at mid-height of the wallpanel, and which load is opposed by linear opposing blocking ofcorresponding lengths at the top and bottom of the wall panel.

Referring to FIGS. 1-5, in general, the inner and outer layers of thewall section are e.g. about 0.75 mm to about 12.7 mm (about 0.03 inch toabout 0.5 inch) thick, optionally about 1.3 mm to about 5.1 mm (about0.05 inch to about 0.2 inch) thick, optionally about 2.2 mm to about 2.5mm (about 0.085 inch to about 0.100 inch) thick. Thermally insulatingfoam can fill the entirety of the space between the inner and outerlayers 34 and 36. The foam can also fill the studs, as desired.

Wall section thickness “T” (FIG. 5) in the main-run wall section isdefined without respect to the dimensions of any studs 123, andgenerally stops at the surface 25 of what is later defined herein asspace 131. Thickness “T” can be as little as about 2 inches (5.1 cm)between the inner and outer surfaces of the wall, to as much as about 8inches (20.3 cm) or more, as measured between the outer surface of layer34 and the outer surface of layer 36, and ignoring studs 123 forpurposes of defining thickness “T”. Typical wall thickness “T” is about3 inches (7.6 cm) to about 6 inches (15.2 cm).

The top plate and bottom plate can be conventional e.g. wood materials,with suitable waterproofing as appropriate for the intended use. Inorder to avoid issues of moisture contact with wood, typically thebottom plate is a fiberglass-reinforced pultruded resinous structure, ofsufficient thickness and rigidity to provide the level of weight bearingcapacity anticipated as being necessary for supporting the structure tobe supported.

Structural building panels of the invention can be manufactured in anyof the standard dimensional sizes, as well as in a variety ofnon-standard size combinations desired for a particular buildingproject. Thus, for example and without limitation, such panels can haveheights of about 4 feet (1.2 m), which accommodates use of the panels in4-foot (1.2 m) frost walls. Height of about 9 feet (2.7 m) accommodatesuse of the panels in standard-height basement walls and standard-heightabove-grade walls.

Thickness “T” of the main run portion of a panel typically ranges fromabout 3 inches (7.6 cm) nominal thickness to about 8 inches (20.3 cm)nominal thickness. Studs 123 can extend inwardly from such nominaldimensions. Additional bending resistance can be obtained through theuse of studs which extend inwardly from the nominal thickness. Suchstuds typically extend inwardly at least 3 inches (7.6 cm) in order toobtain the desired additional bending resistance, as well as toaccommodate desirable thermal insulation properties, at acceptable costefficiencies while facilitating the application of interior finishes tothe wall. Such insulation properties can be obtained by addingconventional insulation material between studs at the inner surface ofthe panel.

Typically, thickness “T” greater than 8 inches (20.3 cm) is not neededin order to satisfy structural demands or thermal insulation demands inthe light duty building implementations recited herein. However, in someinstances, where extraordinary thermal or structural demands are to beimposed on the building panels, then thickness greater than 8 inches(20.3 cm) is contemplated.

Lengths of the panels is limited only by transportation limitations. Forexample, such panels can be as long as the length of the truck bed whichwill transport the panels to the construction site. Thus, based onvehicle length restrictions on public highways, length is generallylimited to about 40 feet (12.2 m), but can be longer as desired wheresuitable transport is available.

On the other hand, where suitable transportation is available, thepanels can be as long as desired for the purpose intended.

Structural building panels of the invention provide a number ofadvantages. For example, a structural building wall can be manufacturedas a unitary structure to any wall height. Ignoring shippinglimitations, panels can be assembled at the manufacturing site to anydesired length, which may be a generic length, for example 10 feet (3.05m), or 20 feet (6.1 m), 30 feet (9.15 m), or 40 feet (12.2 m), orwhatever length or lengths is or are desired. Wall length needed for aparticular portion of a building wall can be cut from a generic-lengthbuilding panel, at the construction site, to meet specific needs, or canbe fabricated to specific length at the panel manufacturing site. Thusif a shorter length is needed for a particular portion of the wall run,the needed length can be cut e.g. from a 20-foot (6.1 m) section. If alonger length wall piece is needed, either a longer length panel can befabricated at the panel-manufacturing site, or multiple pieces can bejoined together to create the desired length wall section. Such joindercan be done either at the construction site or at the manufacturingsite. The respective building panels can be cut to length, using e.g. acircular saw, a ring saw, or a reciprocating saw, employing e.g. amasonry blade.

Because the wall assembly is made primarily from fiberglass, the resincomposition, and foam, the pounds per cubic foot density, and thus theunit weight per foot of length is relatively small compared to aconcrete wall of corresponding dimensions. For example, a building panel20 feet (6.1 m) in length, 8 feet (2.4 m) in height, and nominally 3inches (7.6 cm) thick, weighs about 725 pounds (329 kg), including studs123, and anchor brackets discussed elsewhere herein.

Similarly, a wall 9 feet (2.7 m) high weighs about 20 pounds per linealfoot to about 60 pounds per lineal foot (about 29.8 kg per lineal meterto about 89.3 kg per lineal meter), optionally about 27 pounds perlineal foot to about 55 pounds per lineal foot (about 40 kg per linealmeter to about 81 kg per lineal meter). Accordingly, no crane isnecessarily needed on site for wall erection at or near ground level, orbelow ground level such as for a foundation wall. Rather, some such wallpanels can be moved by manual labor only. In some instances, a lightduty crane would be helpful.

Rough openings for windows 27 and/or doors 29, illustrated in FIG. 1,can be cut on site as desired, using the above-noted masonry blade.Accessories, and other connections between elements of the wall andbetween the wall and other building elements, can be mounted by drillingand bolting conventional building construction elements/fasteners to thebuilding panel, or by use of self-tapping fasteners driven into thebuilding panel, or by adhesive.

FIG. 5 represents a top view of a portion of a foundation wall,including a 90 degree corner in the foundation wall. FIG. 6 is across-section, in elevation view, of a portion of the foundation wallshown in FIGS. 2-4.

FIG. 5 shows that a substantial portion of the volume of the foundationwall is occupied by the series of cavities 196, filled with low-densityinsulating foam 32. Inner 34 and outer 36 layers offiberglass-reinforced resin form the generic inner and outer layers ofthe wall panels 14.

In general, all the space between the inner surface 57 of the panel andthe outer surface 56 of the panel is occupied by layer 34, by layer 36,by intercostal reinforcing webs 50, or by the foam, whereby little, ifany, of the space between layers 34 and 36 is not occupied by one of theabove-recited panel materials. Typically, substantially all of the innerspace between layers 34 and 36 is occupied by panel materials. By sogenerally filling the space between layer 34 and layer 36, all of thepanel elements are fixed in their positions relative to each other, andare affixed to each other whereby the panel is dimensionally quitestable under designed loading, and a desired level of thermal insulationis provided. Further, the panel is sufficiently resistant tolaterally-directed loads imposed on the panel, from outside thebuilding, whether subterranean ground loads or above-grade e.g. windloads, that such loads are efficiently transferred from outer layer 36to the other members of the panel, and respective portions of layers 34and 36, and intercostals 50, and optionally foam 32, share in thesupport of any one load. The resulting panel is stiff, rigid, andsufficiently strong to support all loads, including severe weatherloads, to which the panel is expected to be typically subjected undernormal use environments in an intended building structure, includingnormal seasonal environmental extremes in the given geographicallocation.

Studs 123 serve multiple functions. As a first function, studs 123 serveas mounting locations, for mounting surface materials such as sheetrock, paneling, or other interior sheet material 129, as illustrated inFIGS. 5 and 6, to form the interior finished surface of the wall asoccupied living space. Referring to FIG. 17, space 131 between the studsprovides channels for running e.g. additional insulation 135, and/orutilities 137 such as electricity, plumbing, and/or air ducting. Suchutilities can also be run internally inside the hollow space 133 insidea stud 123. Another primary function of the stud is that the studenhances both the vertical compressive strength and the horizontal pointloading bending moment resistance strength of the wall. Thus, studs 123and intercostals 250 can be collectively designed to provide asubstantial portion of the desired level of strength for the wall panel.

FIGS. 14, 14A, and 14B illustrate line representations of anchorbrackets 24, 24A, and 24B. A bracket 24, 24A, or 24B is mounted to theinterior surface of inner layer 34 at the top of the wall panel, usingbracket panel 134, and brackets 24, 24A are optionally also bonded tostud 123 through a bracket side panel 138. Referring to FIG. 14, toppanel 136 of bracket 24 extends transversely from, and is joined to, thetop of base panel 134. First and second side panels 138 extendtransversely from, and are joined to, both base panel 134 and top panel136, whereby top panel 136 is supported from base panel 134 and sidepanels 138.

Base panel 134 of bracket 24 is positioned against inner layer 34 of thewall panel 14 and is mounted to inner layer 34 and optionally is mountedto stud 123 at side panel 138. Panels 134 and 138 can be mounted toinner layer 34 and stud 123 e.g. adhesively. Top panel 136 interfaceswith and supports top plate 20, and typically is bolted to the top plateas illustrated in FIG. 6. Bracket 24 serves to transfer a portion of theload, on the top plate 20, to the main portion of the wall panel,thereby making the top plate an integral part of the foundation wall.Other portions of the top plate load are transferred to the wall panelby the surface-to-surface contact between the top plate and studs 123.Still other portions of the top plate load are transferred to the wallpanel by direct surface-to-surface contact between the top plate and thetop of the main run portion of the wall panel, optionally through abracket 48 or 188 as illustrated in FIGS. 6, 6A, 6B, and 15.

One of side panels 138 is used to attach bracket 24 to stud 123, whilebase panel 134 is used to attach the bracket to inner layer 34.Accordingly, the second side panel has no necessary attachment function,and can thus be omitted in some embodiments. Bracket 24A of FIG. 14Aillustrates such embodiment where bracket 24A is the same as bracket 24of FIG. 14, with the exception of providing only a single side panel138. In the embodiment of FIG. 14A, either of panels 134 and 138 can beused facing either inner layer 34 or stud 123.

In addition to transferring compressive loading forces from theoverlying building load, brackets 24 and 24A transfer lateral side loadsfrom the back-fill soil, which act on the wall panel, and transfer suchside load through e.g. bolt 139 to top plate 20 and ultimately to theoverlying floor 40, the side loads being generally dissipated in floor40. Given that brackets 24, 24A depend on being mounted to studs 123,the spacing of brackets 24, 24A is limited to no more frequently thanthe spacing of the studs, whereby some lateral bowing of the wall panelmay be experienced, stud-to-stud between the brackets.

In the embodiment of FIG. 14B, bracket 24B resembles a length of angleiron, but is preferably fabricated from FRP materials, e.g. is pultrudedin such angle configuration. Bracket 24B is conveniently sized at about12 inches (30.5 cm) length, whereby the length of the angle bracketreadily extends between studs 123 on opposing sides of a cavity 131.Each flange 134, 136 extends about 2 inches (5.1 cm) from the joinder offlanges 134, 136, illustrated as 145. Bracket 24B is mounted with thelong dimension of the bracket extending along the length of the panel,between edges 216 and 218, with one of flanges 134, 136 insurface-to-surface relationship with cap 342 (FIG. 6C) or top plate 20,and with the other of flanges 134 and 136 lying against inner layer 34or corresponding other inner surface. Since the length of bracket 24Bextends along the length of the wall panel, the bracket can beadhesively mounted to the top plate along substantially the full widthof cavity 131, from stud to stud. In the alternative, or in addition, aplurality of fasteners can be employed along the length of the bracket,fastening the bracket to cap 342 or top plate 20 at intervals generallyas closely spaced as desired through apertures 141 to prevent lateralbowing of the wall panel between studs 123.

Brackets 24, 24A, 24B can be made from other than FRP materials, but theFRP materials are preferred in order to maintain as much of a commonmaterial identity as reasonably possible throughout the wall structure.

FIG. 6 illustrates, in side elevation view, the interface of top plateanchor bracket 24 with top plate 20. In the illustrated embodiment, thetop plate is a conventional wood board, and is secured to bracket 24 bya bolt 139 through top panel 136. FIG. 6 also illustrates a secondanchor bracket 24 used in supporting the interface between the wallpanel and bottom plate 16. Brackets 24, 24A and 24B can be used at thebottom plate equally well as at the top plate.

FIG. 5 illustrates joining together of two wall panels 14A and 14B usinga corner bracket 160, having male and female connectors at right anglesto each other, which can be used to join two wall panels at a rightangle corner. FIG. 5 also shows in-line joinder of wall panels 14B and14C to each other using respective male 216 and female 218 edges whichare formed in the wall panels as the panel structure is formed, andwherein the male edge is received into, and joined with, the female edgeas part of the process of edge-to-edge joining of adjacent ones of thewall panels. Typically, adhesive or curable resin is used in suchedge-to-edge joining.

FIG. 5A illustrates an exemplary glass schedule for a pultruded panel ofthe invention, wherein studs 123 are integral elements of the panel.FIG. 5A shows three primary structural layers of fiberglass in outerlayer 236, two primary structural layers of fiberglass in inner layer234, a third primary structural fiberglass layer at studs 123, andfiberglass rovings and continuous strand mats or chopped strand mats atintercostals 250. The empty spaces between the illustrated fiberglasselements and the die elements represents space which is occupied by theresin composition in the pultruded structure.

FIG. 5A is in fact an exploded view such that the space indicated forthe resin is especially exaggerated.

FIG. 6 illustrates, in edge view, the addition of a fiberglass/resinsupport bracket 48 (FIG. 13) against the outer surface 56 of the wall.FIGS. 4 and 6 also illustrate, from a side elevation view of the outersurface of the wall, the extension of support bracket 48 as a brickledge, along the full length of the main-run wall section. Bracket 48transfers the weight of overlying bricks 175 to the underlying wall 10.

Still referring to FIG. 6, support bracket 48 extends outwardly from theouter surface 56 of the wall panel a sufficient distance, such as about4 inches to about 5 inches (about 10.1 cm to about 12.7 cm), to supportconventional brick or stone, or any other facing on the outside of thebuilding. As indicated in FIG. 6, after completion of the constructionwork, earth or other backfill 174 typically fills up the excavatedcavity around the foundation wall, to a level at or above brick supportpanel 176, thus concealing bracket 48.

Support bracket 48 can be installed facing inwardly at the top of ane.g. garage wall, thereby providing vertical edge support to asubsequently-poured concrete garage floor. Similarly, bracket 48 can beinstalled facing outwardly at the top of an e.g. garage or other wall,thereby providing vertical edge support to subsequently-installed brickor stone, or to support e.g. a concrete slab garage apron. First andsecond complementary brackets 48 can be mounted, one on top of theother, with brick support panel 176 of the first bracket 48 facing awayfrom the building and the brick support panel 176 of the second bracketfacing into the building. Such use of 2 brackets provides for wallsupport of both an adjoining edge of the garage floor and brick or stoneor other exterior fascia, both of which are adjacent the foundationwall.

A line representation of support bracket 48 is illustrated in FIG. 13.In the upright use orientation illustrated in FIGS. 3, 6, and 13, a basepanel 178 of bracket 48 is oriented vertically along the outer surface56 of building panel 14, and can optionally be bonded to panel 14. Thebrick support panel 176 extends outwardly from the base panel, above thebottom edge of the base panel. A bracing panel 180 extends upwardly fromthe bottom edge of the base panel to the outer edge of the brick supportpanel, transferring upwardly-directed structural support from the basepanel to the outer edge of the brick support panel. An upper panel 182extends horizontally from the top edge of the base panel and terminatesat a downwardly-directed keeper panel 184. Upper panel 182 and keeperpanel 184 collectively mount/hang the support bracket 48 from the topsurface of the wall panel 14.

FIG. 15 illustrates a second embodiment of the support bracket, namely atwo-sided support bracket which is designated as 188. Bracket 188 isdesigned and configured to support both (i) an edge of a garage floorwhich generally abuts the inwardly-facing surface of the foundation walland (ii) a brick or stone fascia, or a concrete slab garage apron, whichcommonly face the outwardly-facing surface of an upper portion of thefoundation wall, as well as to interface with an upstanding e.g.above-grade wall which overlies the foundation wall. The edge of thegarage floor overlies a first support panel of the support bracket andthus loads the support bracket on the inward side of the foundationwall. The brick or stone fascia, or garage apron, overlies a secondsupport panel of the support bracket and thus loads the support bracketon the outward side of the foundation wall. The loads imposed on thesupport panels are passed from the support bracket through thefoundation wall to the footer, and thence to the underlying soil orother natural base which supports the respective wall.

As with support bracket 48, the two-sided support bracket 188 isinstalled at the top of the wall panel such that upper panel 182 bearsupon the top surface of the wall panel. Base panel 178A extendsdownwardly from upper panel 182. Support panel 176A extends outwardlyfrom base panel 178A, and is supported by bracing panel 180A. A secondbase panel 178B extends downwardly from upper panel 182, typically butnot necessarily, a similar distance as base panel 178A so as toterminate at a lower edge having generally the same installed elevationas base panel 178A. Support panel 176B extends outwardly from base panel178B, and is supported by bracing panel 180B.

A single support bracket 188 can thus be used in place of theabove-recited first and second support brackets 48 where a concretegrade-level garage floor abuts the top of the foundation wall and abrick or stone fascia, or garage apron, is mounted to the other side ofthe foundation wall.

Similar to the operation of bracket 48, support panels 176A, 176Btransfer the weight of the overlying e.g. loads of the brick or stonefascia, or garage apron, and the edge of the garage floor, to the wall,thence through the footer, and to the underlying natural base of e.g.soil or rock which supports the building.

As illustrated in FIGS. 6A, 6B, brackets 48, and correspondinglybrackets 188, can be used to support the bottoms of the floor joists orother floor support members below the top of the wall such that the topof the floor 40 is at an elevation no higher than a height which isdefined above the foundation wall a distance less than one time theheight of the floor structure. In the embodiment shown, the top of thefloor structure is at approximately the same elevation as the top of thefoundation wall. The ends of the floor support members are disposedinwardly of the outer surface of the foundation wall and inwardly ofinwardly-facing surface 25 of the foundation wall. The sub-floor andfinished flooring, which overlie the floor support members, can extendbeyond the floor support members as desired such as over panel 182 ofbracket 48. Such lowering of the height of e.g. a ground floor canfacilitate construction for handicapped entry into the building.

Similarly, brackets 48 can be configured to support the bottoms of thefloor joists at any desired elevation below the top of the wall suchthat the top of the floor is at any corresponding elevation, e.g. atheight intervals of 0.04 inch (1 mm), relative to the top of thefoundation wall, up to a height which is about the same as the elevationshown in FIG. 6. Such configuring of brackets 48, 188 can thus be usedto support floor joists corresponding to building floors which are abovegrade as well as building floors which are below grade. For example,where 2 floors of a building are below grade, brackets 48 can be so usedto support floor joists or floor trusses on such below-grade floors, aswell as on one or more above-grade floors.

While brackets 48 and 188 have been described herein as being used withbuilding panels of the invention, brackets 48 and 188, when properlysized and configured, can be used with conventional e.g. concrete wallssuch as frost walls and foundation walls so long as upper panel 182 issized to fit on such conventional wall.

Returning again to FIG. 6, bottom plate 16, as illustrated, can be arather thin, e.g. about 0.18 inch to about 0.50 inch (about 4.6 mm toabout 12.7 mm) thick, stiff and rigid resinous pultrusion which hassufficient stiffness and rigidity to spread the vertical load for whichthe panel is designed, out over substantially the full downwardly-facingsurface area of the bottom plate, thus transferring the vertical load tothe underlying e.g. aggregate stone, or other, fabricated base.

In some embodiments, an e.g. conventional concrete footer 55 (FIG. 3) isinterposed between the natural underlying soil, or clean aggregate stonebase, and the bottom plate 16. In such instance, any of a wide varietyof conventionally available pliable, crushable, and curable liquid,paste, or the like deformable gasketing or other bridging material 51 ofchangeable form, or gasketing or other bridging material of defined butcrushable form, such as sheet material, is laid down on the footerbefore the wall panel is placed on the footer. Bridging material 51 isillustrated as a somewhat irregular thick dark line between concretefooter 55 and bottom plate 16 in FIG. 3. The wall panel is installedover the intervening gasketing or other deformable material before thedeformable material has cured, whereby the small interstices, spaces,between the footer and the wall panel are filled in by the deformablematerial.

When the deformable material cures, the deformable material becomesrigid, whereby the bridging material transfers corresponding portions ofthe overlying load across the potentially-existing spaces, which havebeen filled with the bridging material, thus to provide a continuousload sharing interface between the wall panel and the footer along thefull length of the wall panel. Such bridging material can be anymaterial sufficiently deformable to take on the contours of both thelower surface of plate 16 and the upper surface of the footer, and whichis curable to create the afore-mentioned structural bridgingconfiguration.

Referring again to FIGS. 3 and 6, concrete slab floor 38 is shownoverlying that portion of bottom plate 16 which extends inwardly intothe building from the inner surface 57 of wall panel 14, and inwardlyfrom the channel studs 123. Slab floor 38 abuts the inner surfaces ofwall panel 14 and channel studs 123, thus stabilizing the bottom end ofthe wall panel against inwardly-directed forces which reach the lowerend of the wall panel. In some embodiments, bottom plate 16 extends onlyas far as the end panels 130 of studs 123.

As desired, brackets 24, 24A, 24B can be further secured to studs 123and/or main run wall section 22 by employing conventional fasteners suchas screws or bolts through apertures 141 in base panels 134 or sidepanels 138 of the brackets.

Mechanical connecting structures such as bolts, screws, or brackets arespaced along the length of the wall, anchored in and extending fromstuds 123, or anchored in and extending from the main run portion of thewall panel, below the top of the concrete slab 38.

Another exemplary connecting structure is one or more lengths ofreinforcing steel bar (rebar) or a fiber reinforced polymeric (FRP)rebar, which extends along the length of the wall panel, and through oneor more of the studs. For example, a short bar can be used at each stud,extending out of each leg of the stud. Or a single bar can extendthrough one or more studs, or all of the studs in a given wall panel,whereby the length of the rebar generally corresponds to the length ofthe panel. The fluid concrete flows around such connecting structuresbefore the concrete hardens such that the hardened concrete grasps suchconnecting structure, and is thus held to the connecting structure, thuspreventing the concrete slab from pulling away from the wall. FIGS. 6and 6A illustrate such mechanical structure, e.g. a rebar, in end viewat 143, extending from a stud and along the length of the panel.

As a combination structure, bracket 24B can be fabricated as a “U”shaped channel bracket, having base panel 134, top panel 136, and abottom panel 147 opposing top panel 136. Such bracket is installedadjacent bottom plate 16 with base panel 134 oriented horizontallyagainst bottom plate 16, with top panel 136 against inner layer 34, andwith bottom panel 147 parallel to and spaced from top panel 136, wherebybottom panel 147 can serve the function of being grasped by floor slab38.

While described using differing nomenclature, namely wall surface andinner surface, inner surface 57 and wall surface 25 both represent thesame face of wall panel 14 when considered away from studs 123. Contraryto surface 25, inner surface 57 also includes the respective surface ofthe wall panel at studs 123.

Inwardly-directed forces which reach the upper end of the wall panel areopposed by the attachments between the overlying main floor 40 and topplate 20. Inwardly-directed forces which are imposed on wall panel 14between the top of the wall panel and the bottom of the wall panel aretransferred to the top and bottom of the wall panel through thestiffness and rigidity of the wall panel as collectively defined by theinteractions of the structure defined by layers 34 and 36, intercostalwebs 50, foam 32, and studs 123 if used. Other reinforcing structure canbe included, added to the wall if and as desired in order to achieve thedesired level of lateral strength and rigidity in the wall structure.Such loads are transferred to the slab floor 38 at the bottom of thewall by abutment of the concrete slab against the wall; and aretransferred to the overlying floor at the top of the wall throughbrackets 24, 24A, 24B as applies, and bolts 139 where used, or throughcap 342, top plate 20, and fasteners 362.

In residential construction, a typical maximum vertically-directed loadexperienced by an underlying e.g. foundation wall is about 3000 poundsper lineal foot to about 5000 pounds per lineal foot (about 4170 kg perlineal meter to about 7450 kg per lineal meter). The vertical load canbe applied to the full width of the top of the wall anywhere along thelength of the wall, including to studs 123.

Referring to FIG. 5, a typical wall panel of the invention, for use insingle-family residential underground applications such as foundationwalls, has a nominal thickness “T” of about 3 inches (7.6 cm). Studs123, if used, for example as in FIGS. 5, 6 and/or 17, project away fromthe outer layer a distance of about 3.5 inches (8.9 cm) from innersurface 25 of the wall panel. Inner layer 34, outer layer 36, andreinforcing intercostals 50 are all about 0.09 inch (2.3 mm) thick.Studs 123 have walls about 0.09 inch (2.3 mm) thick. Foam 32 has adensity of about 2.0 pcf (32 kg/m³) to about 5 pcf (80 kg/m³). Suchtypical wall panel has a vertical crush resistance capacity of about15000 pounds per lineal foot (22,313 kg per lineal meter). Thedistance/depth by which studs 123 can extend away from the outer wallpanel can vary from about 1 inch (2.5 cm) to about 10 inches (25.4 cm).The ratio of stud depth to stud width generally ranges from about 1/1 toabout 3/1. Depth of less than 1 inch (2.5 cm) provides little in the wayof either strength benefits or room for utility runs. At greater thanabout 6 inches (15.2 cm) depth, the absolutely greater widths of thestuds suggest lesser value to the stud concept, compared to a thickermain run wall section.

Both the vertical crush resistance and the horizontal point loadingbending moment resistance can be designed for relatively greater orlesser magnitudes by specifying, for example and without limitation,density of included foam; thickness of layers 34 and/or 36, and/orintercostal webs 50; wall thickness, spacing, and/or depth “T1” (FIGS. 5and 17) of studs 123, or thickness “T” of the panel, or thickness “T” incombination with depth “T1” of the studs.

Panels expected to be used in below-grade applications are designed tosatisfy the load requirements experienced in below-grade applications,while panels expected to be used in above-grade applications aredesigned to satisfy the load requirements experienced in above-gradeapplications. Such design process includes considering weather and/orground movement history of the use location, as well as otherenvironmental factors. Thus, building panels of the invention include awide range of panel structures and properties, so as to provideengineered solutions which can be designed to fit the stressenvironments expected to be imposed on the specific building panelswhich are to be used in specific uses. One can, of course, also makebuilding panels of generic design which are designed to tolerate a widerange of expected loadings. For example, a first design specificationcan be made to satisfy most below-grade uses while a second designspecification can be made to satisfy most above-grade uses. Suchstandardization can reduce per unit processing costs, while acceptingmaterial costs which are excessive for many of the intended uses.

Given the conventional wisdom that concrete generally does not deflectbefore failing catastrophically, and that concrete is conventionallyused in below-grade foundation walls, applicants believe that there isno universally-recognized standard regarding an allowable amount oflateral deflection of such wall under load.

Given that walls of the invention are made from FRP compositions, whichcan tolerate some deflection without catastrophic failure, one of skillin the art can predict that walls of the invention may deflect underrated load.

FIG. 6C is another enlarged view embodiment of a top portion of anotherfoundation wall structure. In the embodiment illustrated in FIG. 6C, themain run portion 22 of the wall panel is filled with foam as indicatedat 32 and as generally shown in e.g. FIGS. 5 and 19. Inner layer 34 ison the inner surface of the foam. Outer layer 36 is on the outer surfaceof the foam. Inner layer 34 also extends about the plurality ofupstanding studs 123 which are spaced along the length of the wallpanel, and which extend, from the inner surface of the foam, away fromthe outer layer to end panels 130. In general, the wall panel 14illustrated in FIG. 6C can represent any and all of the wall panels ofthe invention where studs 23, 123 extend, from the main run portion ofthe wall panel, away from outer layer 36.

Structural cap 342 covers the top of the wall panel, including the mainrun wall portion, the studs, and the utility cavities 131 between thestuds, and extends downwardly over both the outer face of the wall paneland over the inner faces of the studs. Thus, cap 342 has a horizontalplate 344 which overlies and contacts the top of the wall panel.Horizontal plate 344 generally extends the full length of the wallpanel, and extends from the outer surface of outer layer 36 to theexposed exterior surfaces of end panels 130 of studs 123. An innerflange 346 extends downwardly from the inner edge of horizontal plate344 to a first distal end 348. An outer flange 350 extends downwardlyfrom the outer edge of horizontal plate 344 to a second distal end 352.

Cap 342 is affixed to wall panel 14. A wide variety of methods can beused for such affixation. For example, the cap can be adhered to thewall panel at the respective interfacing surfaces using conventionallyavailable construction adhesives. In the alternative, screws or othermechanical fasteners can be applied spaced along the length of the wallpanel, e.g. through inner flange 346 and into studs 123, and throughouter flange 350 and into the main run wall section, thus to anchor cap342 to the underlying wall panel.

In the illustrated embodiment, top plate 20 overlies cap 342. Top plate20 spreads the load of the overlying floor 40 and other structure overthe entirety of the top plate 344 of cap 342.

Rim joist 354 overlies and bears on top plate 20, and extends along thelength of top plate 20, cap 342, and thus along the length of therespective wall. A plurality of floor joists or floor trusses 356 arespaced along the length of top plate 20, and thus along the length ofrim joist 354, and extend transversely from rim joist 354 into thebuilding, thus to provide support for the overlying floor 40.

Overlying conventional wall plate 358 overlies floor 40. Wall plate 358and its overlying structure, shown only in nominal part, represent theoverlying walls which enclose the respective floor/story of the buildingalong with all other building structure, and the associated loads, whichultimately bear on the foundation wall through floor 40, joists ortrusses 356, rim joist 354, top plate 20, and ultimately cap 342.

Rim joist 354 is affixed to top plate 20 by a plurality of nails orscrews 360 which are spaced along the length of the plate and rim joist.Wall plate 358 is screwed or nailed into the floor joists and rim joiste.g. by a plurality of screws or nails 364.

A plurality of anchor screws 362 extend upwardly in the utility runcavities/spaces 131 between the studs 123, through cap 342, through topplate 20, and into joists or trusses 356. The threads on the screws biteinto the material of joists or trusses 356, and thus provide directanchor links, spaced along the length of the wall of the building,between the foundation wall 12 and the overlying floor whereby risk ofmovement of the overlying building structure off the foundation, e.g. inthe face of extreme environmental stresses, is substantially diminished.Screws 362 are readily applied/inserted after erection of the foundationwall because of the availability of cavities 131 between the studs.

Where a space is available within the overlying structure, such as abovethe bottom stringer of a floor truss, vertically upwardly extendingbolts can be used in place of the vertically upwardly extending anchorscrews, and nuts and optional washers can be used on the bolts, therebyto secure the truss or other overlying structure to the underlying wall.Other vertically upwardly directed mechanical fasteners such as nailscan be used in place of the recited and illustrated screws, so long asthe respective fasteners provide the desired level of securement betweenthe overlying structure and the underlying wall. In the illustratedembodiments, cavities 131 provide access through the bottom of the capfor application of such fasteners into joists or trusses 356. Otheraccess cavities may be provided as desired, in addition to or in placeof cavities 131, for the purpose of providing driving access for drivingfasteners through the cap and into the overlying structure.

The specifications for cap 342, other than the cross-section profile,are generally the same as for bottom plate 16. Thus, a cap which is apultruded structure e.g. 0.09 inch (2.3 mm) to about 0.5 inch (12.7 mm)thick is generally satisfactory for general-purpose use in typicalsingle-family residential, light commercial, and light industrialconstruction. In any event, cap 342 is sufficiently thick, dense, andrigid to provide effective compression and bending support, thus tospread the weight or other loads of the overlying building structureover the top end of, and onto, the wall panel, including onto the mainrun wall section and onto studs 123.

Cap 342 can, in the alternative, be made of overlapping layers offiberglass, impregnated with a curing resin, and subsequently cured, asdiscussed herein with respect to bottom plate 16.

Still referring to FIG. 6C, in some embodiments, top plate 20 can beomitted, whereby cap screws 362 extend from cap 342 directly into joistsor trusses 356; and nails or screws 360 extend from rim joist 354directly into cap 342, optionally with starter holes being previouslyfabricated in the rim joist and cap. In such embodiments, cap 342performs the function recited above for the cap, as well as thefunctions typically performed by top plate 20.

In the alternative, cap 342 can be omitted, top plate 20 can be secureddirectly to the underlying panel, and screws 362 extend through topplate 20 and into the overlying floor structure. One way of securing thetop plate to the wall panel is to position a bracket 24B in the cornerdefined by panel 14 and top plate 20 such that one flange of the bracketis against the inner surface of the wall panel and the other flange isagainst the top plate. Screws through the respective flanges thussecures the top plate to the wall panel.

FIG. 6D illustrates a wall like that of FIG. 6, with lateral soil forcevectors applied at 1-foot (0.3 m) intervals along the height of thewall. FIG. 6E illustrates the same lateral soil forces in table form forthree different wall heights, for each of three different soil types.

In developing wall panels and walls of the invention, the inventorsherein have determined that acceptable lateral deflections in wallpanels of the invention are generally related to the overall height ofthe wall for a given floor of the building, according to the formula

H/240=maximum allowable deflection, where “H” and the allowabledeflection are both expressed in the same unit of measure.

For example, a foundation wall having a height of 9 feet/108 inches (2.7m) has a maximum acceptable deflection calculated as follows:

108 inches/240=0.45 inches maximum allowable deflection

(274.3 cm/240=1.14 cm maximum allowable deflection)

Example

Walls made according to this invention can readily satisfy the abovedeflection standard, given the following specification:

Panel height 108 inches (2.7 m) Overall thickness 6.88 inches (17.5 cm)Thickness, main run wall section, incl layers 3.25 inches (8.3 cm) 34and 36 Stud depth 3.63 inches (9.2 cm) Thickness of layers 34, 36 0.09inch (2.3 mm) Thickness of stud side walls and end panels 0.09 inch (2.3mm) Glass specification as described hereinafter with respect to FIG.5A.

Applicants have surprisingly discovered/observed that, when uprightwalls and wall panels made according to the above specification aresubjected to top/compressive loads which are evenly distributed fromouter layer 36 of the main run wall section to end panels 130 of thestuds, such walls and wall panels deflect outwardly of the building,toward outer layer 36, 236, namely toward the soil back fill. Thus, thenatural horizontal/lateral soil loading applied by the backfilled soil,is at least in part countered by opposing forces resultant from thecompressive building load. As the wall deflects against and toward thebackfilled soil, that portion of the compressive/gravity load of thebuilding which is expressed outwardly is thus dissipated in the adjacentback-filled soil. Thus, the outward wall deflection, resulting from theoverlying building load, balances out some or all of theinwardly-directed horizontal soil loading on the wall. As a result,these opposing lateral forces on the wall tend to balance each otherout, thereby leaving a relatively lower resultant horizontal load on thefoundation wall. While the inwardly-directed soil loading can becalculated as in FIG. 6E, the magnitude of the outwardly-directedbuilding load depends on the overlying building structure as well as onthe structure of the wall panels and walls.

While choosing to not be bound by theory, the inventors hereincontemplate that such outward deflection may be a result of the loadcenterline “C/L” (FIG. 5) along the horizontally-measured length of theupright wall panel, being spaced inwardly into the building from innerlayer 34, from inner surface 25. Given a general balancing of strengthsper lineal foot in inner layer 34, outer layer 36, stud legs 128, andstud end panels 130, the load-bearing capacity of studs 123 may be lessthan the load-bearing capacity of the main run wall section, wherebystuds 123 may compress to a greater degree than the main run wallsection, which greater stud compression would translate to an outwarddeflection of the wall toward the soil back fill.

Thus, it would appear that such outward wall deflection can be expectedany time the centerline of the load balance overlies cavity 131 and theload capacities of the stud skin layers approximate the load capacitiesof inner and outer layers 34, 36.

Returning to FIG. 1, as suggested above, conventional steel I-beams canbe used in combination with wall panels 14 of the invention. Asillustrated in FIG. 1, such I-beams are supported from the underlyingsoil at conventional spacings by posts 28 which transmit loads from theI-beam to the underlying soil, through a load-spreading pad 30. Inconventional structures, the load is transmitted by a conventional steelpost, to an underlying footer pad of concrete which is poured on theunderlying soil.

In the invention, in the interest of avoiding need of a ready-mix truckfor small loads, thus in place of a concrete footer, multiple layers ofreinforced polymer composite are used in fabricating a support pad 30. Atypical such support pad 30 is illustrated in FIG. 7, underlying asupport post and supporting a structural floor-support beam 26.

A cross-section of a representative pad 30, on an underlying supportbase SB is illustrated in FIG. 8A. As illustrated in FIG. 8A, pad 30 hasan upwardly-facing top 30T and a downwardly-facing bottom 30B. Thesurface area of the bottom of the pad is selected to be large enough tospread the overlying load over enough of the natural soil and/or rockunderlying support base that the underlying support base can support theoverlying load over a generally indefinite period of time withoutdeleterious deformation or flow, whether vertical flow or transverseflow, or other movement of the underlying support base. The pad isconstructed of a plurality of generally-extending ones offiberglass-reinforced polymer composite layers 31. The layers are, ingeneral, positioned such that at least a substantial portion of arelatively overlying layer overlies a substantial portion of arelatively underlying layer. Typically, the layers are stacked one ontop of the other, optionally connected to each other at the edges 33, asby folding one layer into a next-adjoining upper or lower layer, suchthat the respective stacking of the layers, layer on layer, results infacing, generally horizontally disposed, portions of the respectivelayers supporting each other, and acting collectively, thus to providepads having sufficient bending resistance to bear downwardly-directedloads when the pads are in use.

Such layering can be created by folding and stacking a resin-wettedfiberglass layer in a wet mold, closing the mold and evacuating the air,thus to consolidate the pad, then curing the resin, resulting in thehardened fiber-reinforced polymeric pad. In the alternative, thefiberglass layering can be placed in a dry mold in dry condition, andthe resin can be infused into the mold while the mold is beingevacuated.

Pad 30 is illustrated in FIG. 7 as having a generally square or roundprojected area, and as being used for spot support such as in support ofa post 28. Pad 30 can have an expanded projected area of any desiredprojected configuration such that a single pad underlies and supportsmultiple posts in an area. Further, pad 30 can have an elongateconfiguration whereby pad 30 can be used as an elongate footer under,and supporting, any number of foundation panels 14 when such panels areused in a fabricated foundation wall.

Thus, a typical support pad can have a projected area of about 1 squarefoot (0.09 m²) to about 10 square feet (0.9 m²) when designed to supporta point load such as a single post. A pad which is designed to supportan e.g. elongate load such as a wall having a length of e.g. 10 feet(3.05 m), 20 feet (6.1 m), 40 feet (12.2 m), or more has an elongatedimension corresponding in magnitude to the length of the wall.

The thickness of the pad is designed to support the magnitude of theanticipated overlying load. Thus, as with the building panels, for eachbuilding application, the pad represents an engineered solution based onthe anticipated load and load distribution. Magnitude of the load assupported by pad 30 generally corresponds to the load distributionconventionally contemplated for typical single-family residentialconstruction. Thus, the load distribution recited herein for foundationwalls can apply such that an elongate pad can support at least 5000pounds per lineal foot (7500 kg/lineal meter) and a round or square padcan support loads of at least about 2000 to about 5000 pounds per squarefoot (about 9760 to about 24,400 kg/m²), more typically at least3000-5000 pounds per square foot (about 14,640 to about 24,400 kg/m²).Higher loadings can be supported by suitably engineered such pads.

The thickness of a pad, between top 30T and bottom 30B depends in parton the load magnitude and load distribution, and in part on the specificresin as well as the specific structure of the reinforcing fibers andfiber layers, as well as on the nature of the construct of the pad. Forlight-weight construction, where the pad carries a relatively lighterload, the thickness of the pad can be as little as 1 inch (2.5 cm)thick. Where the pad bears heavier loads, the pad is thicker, and hasgenerally the same order of magnitude of thickness that would have beenused if the material were steel-reinforced concrete. Thus, pad thicknesstypically ranges from about 3 inches (7.6 cm) thick to about 16 inches(40.6 cm) thick, optionally about 6 inches (15.2 cm) thick to about 16inches (40.6 cm) thick, optionally about 8 inches (20.3 cm) thick toabout 16 inches (40.6 cm) thick, with all thicknesses between 1 inch(2.5 cm) and 16 inches (40.6 cm) being contemplated. Thicknesses lessthan 3 inches (7.6 cm) and greater than 16 inches (40.6 cm) arecontemplated where the anticipated vertical load and load distribution,along with the material properties, indicate such thicknesses.

In general, the dimension of thickness is less than either the length orwidth dimension. As illustrated in e.g. FIG. 1, typically the magnitudeof the thickness dimensions is no more than half as great as themagnitude of the lesser of the length dimension or the width dimension.

In any event, the structure shown in FIG. 8A is not limiting as to thelayer structuring. For example, the layers of fiberglass can beconfigured as an elongate roll, where relatively outer layers arewrapped about one or more relatively inner or core layers.

In the alternative, as illustrated in FIG. 8B, pad 30 can be a pultrudedfiberglass-reinforced polymeric structure such as a solid pultrudedplate or a rectangular tube positioned such that one or more cavities 37extend generally horizontally through the structure. Such rectangulartube has a generally horizontal top or inner web 30TW, a generallyhorizontal bottom or outer web 30BW, and one or more generallyupstanding connecting webs 35 which support the top web from the bottomweb. In the embodiment illustrated in FIG. 8B, cavities 37 are hollow.In other embodiments, a honeycomb or other web structure extends thelength of the cavity 37, thus providing bridging structure between topweb 30TW and bottom web 30BW, which can provide structural supportsupporting the top web from the bottom web and thereby take on some ofthe support function of connecting web or webs 35.

The post 28 is generically represented in FIG. 1. While post 28 can besteel, and pad 30 can be concrete where wall panels of the invention areused, the invention contemplates that post 28 is a hollowfiberglass-reinforced polymer composite structure. Curing resin as inthe pad and building panels can be used to mount and bond post 28 to thepad, with conventional shimming as desired.

Such resin-fiber composite post 28 has a generally enclosing structuralsidewall. The post sidewall is made of fiberglass-reinforced polymercomposite or other fiber reinforced resinous structure. The thicknessand rigidity of the post sidewall is designed as known in the art tocarry a specified load, thereby to support the weight of an overlyingportion of typically an above-grade structure, though below gradestructures can be supported as well. The enclosing post sidewall definesan interior chamber disposed inwardly of the enclosing sidewall. Theinterior chamber is typically empty, but can contain structural ornon-structural material as desired.

Where a fiberglass post 28 is used, a fiberglass-reinforced polymercomposite cap 58 is typically mounted over the top of the post. Cap 58has a top wall 60, and one or more downwardly-depending structuralskirts 62. Top wall 60 of the cap is sufficiently thick and rigid toreceive the load from the overlying beam and transmit the load generallyuniformly about the perimeter of the upstanding outer wall or walls ofthe post, including where the outer walls may be disposed laterallyoutwardly from the edges of the beam. The structural skirt or skirts areconfigured such that, when the cap is mounted on the post, with the topwall of the cap bearing down on the top of the post, the inner surfaceof the structural skirt or skirts is/are in generally surface-to-surfacecontact with, or close proximity with, the outer surface of the post,such that the skirt structure receives and absorbs typically-encounteredlateral forces and transfers such lateral forces to the sidewall of thepost, thereby preventing the top of the cap from moving laterallyrelative to the top of the post.

The cap distributes the lateral loads to the post side walls withlimited bending of the top wall of the cap, so as to utilize theload-bearing capacity of the post sidewalls, from at or near the upperedge of the post, along the full height of the post to the underlyingpad 30. The cap skirts thus capture lateral forces and transfer suchlateral forces to the post.

An alternative to cap 58 is to use a conventional adjustable screw 59 onthe top of post 28. Such screw 59 can be used in place of cap 58, or incombination with cap 58, e.g. between cap 58 and overlying beam 26.Where both cap 58 and screw 59 are used, a suitable screw/cap interfaceis configured in the screw and/or cap to ensure suitable cooperation ofthe cap and screw with respect to each other.

FIG. 9 illustrates a square fiberglass-reinforced polymer composite pad30 of the invention, a square fiberglass-reinforced polymer compositepost 28 of the invention, and a square fiberglass-reinforced polymercomposite cap 58 of the invention. FIG. 10 illustrates a pad/post/capcombination similar to that of FIG. 9 but where the pad is tapered fromthe top of a base of the pad upwardly to where the pad meets the post.FIG. 11 illustrates a pad/post/cap combination similar to that of FIG. 9but where the post, the pad, and the cap are circular. FIG. 12illustrates a pad/post/cap combination similar to that of FIG. 11 butwhere the pad is tapered from the top of a base of the pad upwardly towhere the pad meets the post.

While the pad/post/cap combinations shown in FIGS. 9-12 can be used onthe interior of the building such as in a basement post arrangement assuggested in FIG. 1, a primary purpose of the invention, of avoiding theneed to bring a ready-mix concrete truck to the construction site, isadvanced by using pad/post/cap combinations such as those illustrated inFIGS. 9-12 in applications outside the foundation of the building, suchas to support a deck, a porch, a patio, a light post, or otherappurtenance. In such application, the pad and post are set in theground below the frost line. The post is then cut off typically, but notnecessarily, below grade. Conventional structure such as a 4×4 treatedwood post is then mounted to the top of cap 58, and the cap issubsequently mounted, e.g. adhesively mounted, to the top of the post,with the cap skirt extending below the top of the post. With the e.g.4×4 post thus extending upwardly from the cap, with the cap permanentlye.g. adhesively mounted to the post, the hole is filled to grade suchthat only the conventionally-used wood post remains visible. Thus,typical outside appurtenances to the building can be completed, againwithout any need to bring ready-mix concrete, or concrete block, to theconstruction site, and with only conventional materials being visibleabove the finished grade. This can provide a significant time and costadvantage when only a small amount of concrete would have otherwise beenneeded, as the trucking cost is fixed, even for a small quantity ofready-mix concrete.

In other embodiments, the fiberglass post 28 can extend above finishedgrade, and can support any of a wide variety of suitable overlyingstructures from above-grade joinders.

As indicated above, one of the objectives of the invention is to usewall panels and accessory structure in places, and for structuralpurposes, where concrete would conventionally be used. Use of concretein foundation walls is common, and the products of the invention arereadily adapted to be used in foundation structures.

In some conventional implementations of buildings in areas withsubstantial seismic activity, reinforced concrete has been used in thebuilding foundation. However, even when heavily reinforced with steel,concrete can crack and crumble during seismic activity. By contrast,walls and wall panels of the invention, engineered to the same orsimilar load-bearing requirements successfully withstand/toleratesubstantially greater seismic loading before structural failure. In anyevent, walls of the invention do not crumble, or rack.

Where e.g. seismic activity imposes substantial side loads, extendingalong the length of the wall, a conventional concrete wall cannotdeflect, but will instead crumble. Such loads on wood frame walls causesuch wood frame walls to rack, e.g. to convert from rectangles tosomething resembling parallelograms. By contrast, walls of the inventioncan deflect outwardly, optionally inwardly, but are not substantiallyracked by seismic activity, do not crumble, and can withstand greatersuch side loads than typically-used concrete structures.

In more tropical climates, above-ground outside walls are, in someinstances, required to be built with concrete for the purpose of, amongother advantages, inhibiting mold growth. Where high wind conditions,such as hurricanes or tornadoes, are common, above-grade outside wallsare, in some instances, required to be built with concrete in order toachieve a level of lateral strength, against perpendicularly-directedwind and rain forces, which can withstand such forces.

In such situations, such as in areas frequented by hurricanes ortornadoes, above-ground wall structures of the invention can be used inplace of concrete, while achieving the lateral strength which canwithstand such forces, and at the same time avoiding the e.g. waterpenetration, and other, limitations inherent in concrete. Accordingly,the wall structures of the invention are contemplated to be useful inabove-ground applications as well as below-ground/foundation wallapplications.

The Fiber

The reinforcing fiber materials used in pultruded products of theinvention can be selected from a wide variety of conventionallyavailable fiber products. Glass fiber has been illustrated in thegeneral description of the invention, and is believed to be the mostcost effective material. Other fibers which are contemplated as beingacceptable include, without limitation, carbon fibers, Kevlar fibers,and metal fibers such as copper and aluminum. Other fibers can beselected to the extent their reinforcing and other properties satisfythe structural demands of the building panel applications contemplatedin the invention, and so long as the fibers are not pre-maturelydegraded in the use environment contemplated for the respective wallpanels.

To that end, use of cellulosic fibers is limited to those compositionswhere the cellulosic fiber can be suitably protected from thedeleterious affect of moisture reaching the fiber and degrading thefiber. Thus, use of cellulosic fiber without moisture protection in theinvention is generally limited to less than 10 percent by weight of theoverall composition of a given structural element, e.g. panel, bracket,or the like. However, where the fiber is impregnated with a suitablequantity of resin, and the resin protects the cellulosic fiber fromattack by moisture, such composite compositions can be used atconcentrations greater than 10 percent by weight cellulosic fiber.

The lengths, widths, and cross-sectional shapes of the fibers areselectable according to the structural demands of the structures inwhich the building panels or other structures are to be used. Similarly,the structures of the fiberglass manufactured products which areincorporated into the panel can be selected according to the structuraldemands which will be placed on the panels. Those skilled in the art arecapable of making such selections.

FIG. 5A provides a representative example of a glass schedule which canbe used to make panels useful in exterior wall construction as describedelsewhere herein. FIG. 5A shows the fiberglass layers/elements disposedabout foam blocks 232 in the main run wall section of the panel andabout foam blocks 232A in studs 123.

Starting from the outside of the panel, the outermost layer offiberglass is a ½ ounce per square foot (128 g/m²) glass surface veil260. Inwardly of the surface veil are first and second layers 262, 264of 18 ounce per square yard (612 g/m²) unidirectional rovings each witha 1 ounce per square foot (255 g/m²) chopped strand mat, wherein thechopped strand mat is in each instance disposed outwardly of therovings, toward outer veil 260. Thus the fiberglass in outer layer 236of the panel is defined by fiberglass layers 260, 262, and 264.

The fiberglass at intercostals 250 is a series of 18 ounce per squareyard (612 g/m²) rovings 266, with 1 ounce per square foot (255 g/m²)chopped strand mat 268 disposed on each side of the rovings between foamblocks 232 and the rovings.

An intumescent veil 270 of fiberglass mat coated with intumescentmaterial is the innermost fiberglass layer in the panel. An intumescentmaterial is a material which swells, enlarges, or bubbles up, andtypically chars when exposed to flame and forms an insulatingfire-retardant barrier between the flame and the material/substratewhich bears the intumescent material. A suitable intumescent material isavailable as TSWB powder from Avtec Industries, Hudson, Mass. The TSWBpowder can be added to a fiberglass veil by e.g. dispersion coating.

In the alternative, the intumescent material can be added to the resinwhich will form the innermost layer of the panel.

Next inwardly of intumescent veil 270 is a layer 272 of 24 ounce persquare yard (816 g/m²) unidirectional rovings with a 1 ounce per squarefoot (255 g/m²) chopped strand mat 274 disposed between the rovings andthe intumescent veil.

On studs 123, next inwardly of layers 272 and 274 is a layer 276 of 24ounce per square yard (816 g/m²) rovings, extending along the legs 128,and the end panels 130, of the studs adjacent foam blocks 232A.

Between layers 270, 272 and 274, and foam blocks 232, is a layer 278 of18 ounce per square yard (612 g/m²) unidirectional rovings with a 1ounce per square foot (255 g/m²) chopped strand mat 280 between rovingslayer 278 and rovings layer 274, with rovings layer 278 and choppedstrand mat layer 280 being disposed between foam blocks 232 and 232A atstuds 123. Thus the fiberglass in inner layer 234 of the panel isdefined by fiberglass layers 270, 272, 274, 278, and 280.

Referring again to FIG. 5A, in each stud, one of the legs 128 is alignedwith one of the intercostals 250, such that a load transmitted throughthe respective intercostal is readily transmitted into the respectiveleg 128 of the adjacent stud.

Now that a specific glass schedule has been illustrated for an exemplarywall panel, those skilled in the art can readily devise other glassschedules to meet the needs of other implementations of the invention.

The Polymer

The polymer which is used in the pultrusion process, and optionally usedas an adhesive for joining elements of the structure to each other, canbe selected from a wide variety of conventionally availablemultiple-part reaction-curing resin compositions and thermoplastic resincompositions. Typical reaction curing resin is a 2-part liquid where twoliquid parts are mixed together before the resin is applied to the fibersubstrate. Third and additional components can be used in the reactionmixture as desired in order to achieve the desired level of reactioncuring of the resin, as well as to achieve desired properties in thecured resin. The resin mixture should be sufficiently liquidous to bereadily applied and spread about a fiber base sheet/substrate thereby tofill in all of the voids in the substrate and/or to so flow over, under,around, and through the fiber composite in a forming and/or moldingprocess. Examples of useful 2-part reaction curing resins include,without limitation, epoxy resins, vinyl ester resins, polyester resins,polyurethane resins, and phenolic resins. Examples of thermoplasticresins include thermoplastic polyurethanes, acrylics, polyethylenes andother polyolefins. Resin used in pultrusion can also be thermoplasticresins which are embedded in rovings which melt and form the part in thepultrusion die.

Those skilled in the art know that each of the above noted reactioncurable resins represents a large family of reactable materials whichcan be utilized to make the resultant reaction-cured pultruded resinstructure, and are capable of selecting reaction resin combinations forthe uses contemplated in the invention. Suitable reaction curableexperimental resin is a polyester resin available as XV 2979 from AOCManufacturing Company, Collierville, Tenn. In addition, more than twosuch resins can be mixed to obtain a desired set of properties in thereaction product or process.

Similarly, each of the above noted thermoplastic resins represents alarge family of materials which can be used to make the resultant FRPproducts. A suitable thermoplastic resin, especially for web bagmolding, is an acrylic resin available as MODAR from Ashland Inc.,Covington, Ky.

The resin, whether reaction curable or thermoplastic resin, can bemodified by addition of filler to the polymeric composition, in theamount of up to about 200 parts filler by weight to each 100 partspolymer, optionally 30 parts filler to about 100 parts filler per 100parts polymer, optionally about 40 parts filler to about 60 parts fillerper 100 parts polymer. About 50 parts filler to 100 parts polymer hasbeen found to be highly satisfactory. While a variety of fillers can beused for the purpose of reducing cost of the resin component of theresultant panel, alumina trihydrate powder, as conventionally availableas polymeric filler, has been found quite satisfactory in that thealumina trihydrate satisfies the objective of cost containment whileadding a level of fire retardancy. Suitable alumina trihydrate isavailable from Huber Engineered Materials, Atlanta, Ga.

For any set of reaction materials or thermoplastic resins which are usedin the invention, any conventional additive package can be included suchas, for example and without limitation, catalysts, anti-oxidants, UVinhibitors, fire retardants, fillers, intumescent material,fluidity-control agents, whether organic, inorganic, or polymeric, toenhance the process of applying the resin and/or curing the resin,and/or to enhance the properties of the finished product such as weatherresistance, fire resistance, hardness, shrink control, mold lubrication,colorants, fillers, and other desired features.

Each set of two or more materials which can be mixed and reacted to makethe resultant resin product, or each thermoplastic composition, has itsown processing parameters, such as reaction temperature, catalysts, timerequired for a curing reaction to take place, extruder temperature, dietemperature, and the like, along with respective processing equipmentwith which the respective resin is effectively processed. Further, eachset of such two or more reaction materials, or each thermoplastic resincomposition, develops its own set of resultant physical and chemicalproperties in light of the curing or plasticizing, and molding process.Especially the physical properties are influenced by the affect of theincluded fibers and fillers, such that more than two such reactants, ortwo or more thermoplastic resins, may be useful in achieving, in thefinished polymer, a desired set of physical properties.

The Polymer/Fiber Composite

In general, dry fiber strands are used as the fiber base for apultrusion process. E.g. dry fiber substrate, woven cloth, fiber matand/or rovings are used for structural elements of the invention otherthan wall panels, such structural elements as posts, 28, pads 30, caps58, and any of brackets 48, 160, and 188. Where using other than apultrusion process to form a structural element, enough resin is addedto the fiber substrate to fill all voids, whereby there should be no airinclusions, or so few air inclusions as to have no material affect onthe physical or chemical stability, or the physical properties, of thestructural element being fabricated. Overall, the glass/resin ratio isas high as can be achieved while not leaving any significant,deleterious voids in the resultant structural element once the resin iscured.

Given the requirement to minimize voids, and using conventionallayer-development techniques, the resultant structural layer product,e.g. layer 34 or 36, or intercostals 50, or other product, is about 30percent by weight to about 65 percent by weight fiberglass, andcorrespondingly about 70 percent by weight to about 35 percent by weightresin. Optionally, the resultant layer is about 40 percent by weight toabout 60 percent by weight fiber and about 60 percent by weight to about40 percent by weight resin. A typical resultant cross-section is about45 percent by weight to about 55 percent by weight fiberglass and about55 percent by weight to about 45 percent by weight resin, optionallyabout 50 percent by weight fiberglass and about 50 percent by weightresin. Where filler is used, the weight of the filler, as well as allother resin additives, is taken to be part of the above-recited resinfraction.

According to well-known technology, the number of layers of glass, incombination with the weight of the glass per layer, in generaldetermines the thickness of the resultant layer after theresin-impregnated layer is cured. For example, multiple layers of a12-30 ounce per square yard (407-1016 g/m²) layer of woven fiberglasscloth can be impregnated to fill all voids, and to thereby achieve aresultant cured structure which is typically between about 1 millimeterthick and about 12.7 millimeters thick (between about 0.04 inch thickand about 0.50 inch thick). The greater the number of layers offiberglass which are impregnated, typically the greater the thickness ofthe resulting impregnated and cured composite reinforced layer.

Referring to wall panels 14 wherein studs 123 are in an upstanding e.g.vertical orientation, the reinforcing fiberglass fibers arepredominantly oriented to extend in an upright direction, e.g. up anddown, parallel to the studs. Transverse fibers and/or adjacent layershaving transverse fibers, can be used to bond together the uprightfibers, thus to provide a relatively lesser degree of strengthcontributed by the transversely oriented fibers and to fix the laterallocations of the upright fibers.

The bottom plate can be any material which can bear the load imposed onthe overlying wall panel. A typical bottom plate is an e.g. about 0.18inch thick to about 0.50 inch (about 4.6 mm to about 12.7 mm) thickfiber-reinforced pultrusion, which is sufficiently stiff and rigid tospread the overlying load to the underlying soil substrate along thelength of the panel through an e.g. leveled clean aggregate stone base.The stone may be a crushed stone or an uncrushed aggregate stone.

Top plate 20 can be made of, without limitation, fiberglass-reinforced,or other fiber-reinforced, resinous materials, including fiberglassreinforced pultrusions, or other materials such as wood, in the shapeconventionally used for a top plate, or in a novel shape such as thatillustrated at 342. It is contemplated that a conventional wood-basedtop plate serves the purpose adequately, and provides for attachment ofoverlying wood elements such as wood framing, using conventionalfasteners and conventional fastening methods.

The Foam

The purpose of foam 32 can be two-fold. First, the foam can contributeto the structural integrity and strength of the building panel structureby being sufficiently rigid, namely a rigid foam, and sufficientlyaffixed to the adjacent panel elements, that the foam contributessignificantly to fixing the structural layers 34 and 36, and intercostalwebs 50, in their designed configurations under normal loading of thepanel, whether vertical gravitational loading, or lateral loading suchas lateral ground loads in below-grade applications, and lateral windand/or water loads in above-grade applications. Thus, the foam can makea substantial contribution to the dimensional stability of panel 14.

Second, the foam contributes a substantial thermal insulation propertyto the resulting building panel construct.

In achieving a desired level of thermal insulation while retaining thefoam as a rigid closed-cell material, the foam has a density of about 1pound per cubic foot (pcf) (16 kg/m³) to about 12 pcf (192 kg/m³),optionally about 2 pcf (32 kg/m³) to about 8 pcf (128 kg/m³), optionallyabout 2 pcf (32 kg/m³) to about 5 pcf (80 kg/m³). Lighter weight foamscan be used so long as the desired level of thermal insulation isachieved. While heavier weight foams can be used, and typically providea greater increment of structural strength, certain heavier weight foamsmay provide less than the desired level of thermal insulationproperties, and are more costly. In general, the foams used in theinvention are relatively lighter weight closed-cell foams.

Foam 32 can be made from a wide variety of compositions including,without limitation, extruded polystyrene foam, expanded bead polystyrenefoam, rigid urethane foam, phenolic foam, or polyisocyanurate foam. Thefoam is moisture resistant, preferably moisture proof, and is chemicallyand physically compatible with the compositions and structures of layers34 and 36, and intercostal webs 50. A suitable foam board is 2 poundsper cubic foot (32 kg/m³) polyisocyanurate foam, available from ElliotCompany, Indianapolis, Ind.

Foam 32 optionally fills all, or substantially all, of the spacesbetween the respective surfaces of structural layers 34 and 36, andintercostal webs 50, and is in surface-to-surface contact with therespective layers and intercostals as such layers define the cavities inwhich the foam is received. In addition, the foam is adhered to therespective structural layers and intercostals so as to absorb sheerforces between the foam and the respective structural layers andintercostals.

Blocks 32 of foam can be brought into surface-to-surface relationshipwith the fiberglass and resin as part of the pultrusion process whilethe pultrusion profile is being formed and pultruded and before theresin has set, whereby the foam is in surface-to-surface contact withthe respective layer precursors and becomes wetted with theuncured/plastified resin. With the foam in contact with the in-processfiber-reinforced layer precursor, and wetted by the fiber-reinforcedlayer precursor, the setting of the resin as the thermoplastic resincools, or the reaction curing resin polymerizes, bonds the foam to thestructural layers 34 and 36, and intercostals 50 as applies, whereby noseparate adhesive is necessarily required to bond the foam to therespective structural elements.

Given a typical thickness of the main run wall section, of about 3inches (7.6 cm), given that the cavities 196 are filled with lightweight insulating foam, wall panels of the invention provide thermalinsulation factors between layers 34, 36 of about R15. An additionale.g. R13 can be achieved by installing fiberglass insulation batts incavities 131, thus to achieve an overall insulation factor of about R28in typical walls of the invention, and achieving thermal insulationproperties far superior to most concrete wall products, even insulatedconcrete wall products, currently available to the consuming public.Such superior insulation value can thus decrease heat loss to asubstantially greater extent than most foundation wall productscurrently available to the consuming public.

Throughout this teaching, reference has been made to affixing variouselements of the building panels to each other. In some cases, mechanicalaccessories such as bolts have been mentioned, such as for attaching thetop plate to bracket 24 or 24A or 24B. In instances where two elementsare affixed to each other, and where both elements contain resincomponents, especially reaction-cured components, the curing of theresin in any two such structural elements being formed or joined can beused to affix the elements to each other such that no further adhesiveneed be used. On the other hand, where components are assembled to eachother at the construction site, at least in some instances, use of e.g.conventional construction adhesives and sealants which are known forutility in construction projects, is contemplated.

One example of use of construction adhesive in assembling the foundationwall is affixing the bottom plate to a wall panel. Wall panels of theinvention can be transported to the construction site without top plateor bottom plate, and wherein top plate materials and bottom platematerials can be transported to the construction site separately,although potentially on the same vehicle. Bottom plates and top platesare then affixed to the wall panels at the construction site, asdesired. The bottom plate is typically affixed to the bottom of the wallpanel with a construction adhesive, with or without the assistance ofbrackets 24, and optionally bolts extending generally through thethickness of the wall panel between layers 234 and 236. The top platecan be affixed to the top of the wall panel using brackets 24 and bolts139, and/or other support as needed, and optionally in addition, or inthe alternative, adhesive between the top plate and the top of the wallpanel.

Brackets 48, 160, and 170 can be adhesively mounted to the buildingpanels. In the alternative, where the panels and brackets are made usingcuring resins, the surfaces of the respective parts, including therespective areas of the building panels, can be coated with a supply ofthe curing resin before the parts are assembled, and the parts can thenbe held together for a sufficient time, under known satisfactoryconditions, which result in the curing of the resin, whereby the curingof the resin develops the necessary level of affixation between therespective parts of the wall.

In the same way, either adhesively or by use of curable resin materials,studs 123, support brackets 24, 48, and floor-and-garage apron brackets188 can be mounted to a wall panel after the wall panel reaches theconstruction site.

It will be understood that any affixation of bracket 24 to the innersurface of the wall panel must be generally fully developed as to itsrequired operating strength before the top plate or bottom plate, asapplies, can be affixed to the wall panel and apply its rated load tobracket 24.

FIGS. 5, 17, 18, and 19 show cross-sections of building panels of theinvention wherein inner layer 34, 234 and outer layer 36, 236, areintegral with a structurally-reinforcing bridging intercostal web 250.Studs 123 extend from inner layer 34, 234 inwardly to end panels 130 ofthe respective studs. In the examples of FIGS. 18 and 19, one of thelegs 128 on each of the studs is an extension of a respectiveintercostal web 250, whereby the intercostal and the stud leg functionas in-line supports to each other, thus to form a unitary continuoussupport structure from outer layer 236 to end panel 130, and extendingalong the full height of the wall panel. Studs 123 create a cavity 131(FIGS. 17-19) for running utilities or to add insulation.

Building panels of the invention can be made by, for example, acontinuous pultrusion process or a wet molding process. A pultrusionprocess is, illustrated in FIG. 20, wherein the cross-sectionsillustrated in FIGS. 5 and 17-19 are representative of the productcoming out of the pultrusion die. The pultruded product is producedcontinuously by a pultruder 97. Pultruder 97 receives the scheduledfiberglass feeds, and resin feeds, optionally feeds of foam blocks 32,and forms and sets such materials in the designed configuration. Thethus-formed and set pultruded product is cut by a traveling cut-off saw98 at convenient lengths which represent the height of an upstandingbuilding panel used in e.g. a wall structure.

Referring to FIGS. 18 and 19, the panel, as pultruded, has a generallycontinuous male side 216 and a generally continuous female side 218.

Referring back to FIG. 20, the so cut-off panel lengths traverse aconveyor 100 to a re-directing corner conveyor 102, where the cut-offpanels execute a 90 degree turn while maintaining panel orientation, anddepart the turn conveyor traveling with a leading side edge 104 and atrailing side edge 106. As each panel leaves the turning conveyor, theleading side edge and/or the trailing side edge of the panel is wettedwith adhesive at work station 108 so that facing male and female sideedges of adjacent panels can be adhesively joined together. The adjacentmale and female side edges of adjacent panels are then pushed/urgedtogether, thus joining the side edges of the adjoining panels to eachother as illustrated in FIG. 5. Once the side edges are joined, adesired level of mechanical compression is applied at the joined sideedges, thus to mechanically hold the side edge elements in conjoinedrelationship, e.g. at work station 110 long enough to obtain structuralstability and longevity of the joinder relationship, e.g. until theadhesive material is cured.

Downstream from work station 110, a travelling cut-off saw 112 can beused to cut the so joined panels to any desired length.

Either before or after length cut-off saw 112, the top and/or bottomplates can be applied to the top and/or bottom of the panel atrespective work stations 114, 116. In the alternative, the top and/orbottom plates can be applied to the top and/or bottom of one or morepanels at the construction site.

The top and bottom cut ends are covered by top and bottom plates asdesired, whether in the manufacturing process or prior to installationat the construction site.

In embodiments where the closed cavities 196 in the pultruded structureare empty as in FIGS. 16 and 17, all of the strength in the structure isderived from structural elements 234, 236, and 250, and studs 123 whenpresent. Thus, structural elements 234, 236, and 250, and studs 123, aredesigned as structural members in and of themselves. Thicknesses oflayers 234 and 236, and intercostals 250, and studs 123, can be, forexample and without limitation, about 0.04 inch (1 mm) to about 0.5(12.7 mm) inch for building panels which are to be used for typicalresidential or light commercial or light industrial construction.

Cavities 196 can be used as utility runs as desired. In any of thepultruded structures, cavities 196 can be filled with insulating foam orother known insulating materials, as desired. Rigidity provided by suchinsulating material, if any, can be considered in designing especiallythe thicknesses of structural elements 234, 236, and 250, and the layersin studs 123. Foam can be incorporated into cavities 196 by feedingpreviously-formed elongate blocks 232 of foam into the pultrusion diealong with the fiberglass and resin, whereby the resin flows about boththe fiberglass and the foam, and bonds to both the foam and thefiberglass.

In some embodiments, the foam blocks are already wrapped with one ormore layers of fiberglass before being fed into the pultrusion process.In other embodiments, all of the fiberglass is fed to the pultrusionprocess separate from the foam blocks.

In yet other embodiments, the foam is added into cavities 196 after theresin/fiber composition has been formed and set in the pultrusionprocess. In such instances, a foam-in-place process is used to inject afoamable material into cavities 196.

Exemplary structures of side edges of the pultruded building panels, andjoinders of adjacent panels, are shown in FIGS. 5, 16, and 17. FIGS. 5,18, and 19 show male-female end combinations on building panels 14. Eachpanel has a male edge 216 and a female edge 218. FIG. 16 shows endjoinder structure where both ends 220 of a panel define a first step222A, 222B and a second step 224A, 224B, each panel having the same endstructure at both ends, and all panels having a common end structure. InFIG. 16, end 220A of panel 14A is joined with end 220B of panel 14B.

FIG. 17 shows first and second pultruded panels 14A, 14B, similar to thepanels illustrated in FIGS. 5 and 16, including intercostals 250. InFIG. 17, each panel has a plain end 220A and a receiving end 220B. Areinforcing stud 123 is integral with the receiving end 220B. The plainend 220A of second panel 14B abuts against, and is joined to, thereceiving end 220B of the first panel 14A in making a wall structure,ceiling structure, or floor structure; and inner layer 234 of the secondpanel 14B abuts, against and is joined to, the surface 226 of stud 123on the adjacent panel 14A, surface 226 being that surface of the studwhich faces outwardly in a constructed building when the panel is usedin constructing a building outer wall.

So long as the panels are not cut, the panels can be joined end-to-endusing end structures which have been fabricated as part of the processof initially fabricating the panel. Where an initially-fabricated endstructure of a panel is cut off, such as at the construction site, thecut-off end of that panel can be joined to another panel using e.g. an“H” bracket 140 (FIG. 13A) to make a straight-line joint such as thatillustrated in FIG. 15A.

Referring to FIG. 17, the distance between the receiving edge and theplain edge represents the length of a panel 14. In panels which usestuds 123, and where the panels are long enough, studs 123 are typicallyspaced at industry-standard distances from each other, parallel to eachother, along the length of the panel. Thus, studs 123 are typicallyspaced every 16 inches (40.6 cu) or 24 inches (61 cm) along the lengthof the panel. Where other spacing distances are standard according tolocal practice, a corresponding stud spacing distance is contemplated.

The invention contemplates studs 123 structured as closed structures,such as a closed-perimeter rectangular tube, which may be assembled to apultruded wall panel at desired spacings along the length of the wallpanel. The invention further contemplates a stud 123 as a 3-sidedrectangular e.g. pultruded structure, having opposing flanges on theopen side of the tube, wherein such flanges extend away from each otherand wherein the flanges provide mounting structure for mounting the studto a wall panel e.g. at layer 34.

Studs 123 can be centered over a structurally-reinforcing intercostalmember 50, 250, as in FIGS. 5 and 17, or offset from thestructurally-reinforcing member, with one of the stud legs operating asan extension of the intercostal member, as illustrated in FIGS. 18 and19. Further, studs 123 can be completely displaced from intercostals250.

FIG. 21 shows a wall panel having no intercostal reinforcements, namelyno intercostals 50, 250, and no other reinforcement between the innerand outer layers. FIG. 21 does show an intermediate layer 39 betweenstuds 123 and a foam board 32BD. Foam board 32BD is generally continuousalong the full height and width of the wall panel, and across the fullthickness of the wall panel between intermediate layer 39 and outerlayer 36. Specifications for the foam board 32BD, including polymercontent, density, rigidity, and the like, are the same as for foamblocks 32. Specifications for intermediate layer 39, including fibercontent, polymer content, polymer selection, layer thickness, and methodof making the layer are generally the same as for layer 34, namely layer39 can be made by the pultrusion process as part of the process ofmaking the remaining elements of the panel.

FIG. 21 also shows a reinforcing layer 36R disposed outwardly of outerlayer 36 such that outer layer 36 is between reinforcing layer 36R andthe foam board 32BD. The specifications for layer 36R in the embodimentsof FIG. 21, including fiber content, polymer content, polymer selection,layer thickness, and method of making the layer are the same as forlayer 36, namely layer 36R can be made by the pultrusion process as partof the process of making the remaining elements of the panel.

Layers 36R and 39 are optional. FIG. 22 illustrates an embodiment wherelayer 39 is retained but layer 36R has been omitted. In FIGS. 22, and23, the respective layers are represented by single lines. The structureof FIG. 22 includes foam board 32BD, outer layer 36 on an outer surfaceof board 32BD, intermediate layer 39 on an inner surface of board 32BD,inner layer 34 overlying intermediate layer 39, and studs 123 betweenintermediate layer 39 and inner layer 34. Layer 39 can be omitted suchthat studs 123 lie directly against foam board 32BD. FIG. 22 furtherillustrates an alternate configuration for male 216 and female 218 endson the panel.

FIG. 22 illustrates spacing of the studs 16 inches (40.6 cm) apart, withcorresponding spacing of the male and female ends so as to accommodatecommon construction protocol which spaces studs 16 inches (40.6 cm)apart along the length of the wall for purposes of interfacing suchstuds with commonly available construction materials.

The embodiments illustrated in FIG. 23 are similar to those illustratedin FIG. 22, including intermediate layer 39, with the addition ofreinforcing “T's” 46 adjacent outer layer 36. While “T's” 46 can be madefrom a variety of stiff, rigid materials, FRP materials, similar inrigidity to layers 34, 36 are contemplated. In general, “T's” 46 areaffixed to outer layer 36 so as to absorb and bear especially externalstresses imposed on the wall panel at outer layer 36, thus to directsuch stresses away from outer layer 36 and internally into the interiorof the wall panel.

Wall panels of FIGS. 21, 22, and 23 are conveniently made in pultrusionprocesses wherein the foam board is fed into the pultrusion processingequipment whereupon the respective resin is applied to the foam board,resulting in inherent bonding of the resin to the foam board as theresin cures about the board. Suitable reinforcing fiberglass structurecan be simultaneously fed into the pultrusion process, thus tocollectively position the foam, the resin, and the fiberglass relativeto each other, and to bond the foam, the resin, and the fiberglass toeach other, during the pultrusion process.

In some embodiments, fiberglass layers are mounted to the foam boardbefore the foam board is fed into the pultrusion process.

Where reinforcing “T”'s 46 are used, grooves are optionally formed inthe foam board, and the “T”'s are mounted in the foam board, before thefoam board is fed to the pultrusion process. Construction adhesive maybe used to temporarily or permanently hold the reinforcing “T”'s in thefoam board prior to feeding the foam board to the pultrusion process. Inany event, the curing of the resin about the foam board, and flow of theresin into the “T” grooves, results in the foam board being solidlymounted in the panel, solidly mounted to the foam, and “T's” beingsolidly incorporated into the resulting structure.

Wall panels without studs 123, as in FIGS. 21, 22, and 23, findparticular use in some above-grade applications, where strengthrequirements are less demanding. Such wall panels without studs alsofind use in above-grade applications where thermal insulationrequirements are more demanding than in foundation walls, and/or whereutility cavities 131 are relatively less valuable, which means that agreater overall insulation value can be built into the wall panel aspultruded, by providing a wall panel wherein the main run wall sectionis thick enough (dimension “T”) to provide a uniform thermal resistancealong the full length and height of the wall.

FIG. 24 shows an elevation view of a portion of a wall of the invention,including a footer 53 on an underlying natural base, a bottom plate 16,a wall 10 of the invention, top plate 20, and overlying floor 40. Loads“L1” and “L2” are shown spaced from each other and applying downwardlydirected forces on the wall. Loads “L1” and “L2” represent buildingloads generated by overlying building structure. Loads “L1” and “L2” areintended to represent loads of differing magnitude spaced along thelength of the wall, as representations that loads of different magnitudeare typically imposed on a building outside wall at different locationsalong the length of the wall.

Under each of the loads “L1” and “L2” in FIG. 24, a first cone defininga first relatively narrower angle is defined by dashed lines, and asecond cone defining a second relatively greater angle is defined bysolid lines. The relatively narrower and greater angles of the conesunder each load are intended to generically represent the relativedifference between load distribution in a concrete wall (narrower angle)and load distribution in walls of the invention (greater angle). Thus,FIG. 24 illustrates a substantial functional difference between walls ofthe invention and conventional concrete walls. Namely, relativelyspeaking, concrete walls tend to distribute the load over a relativelysmaller area while walls of the invention tend to distribute the loadover a relatively greater area. The area shaded with horizontal linesrepresents a length portion of the wall where the loads “L1” and “L2”are both supported in part by the bottom portion of a wall of theinvention while a concrete wall has no such load sharing function withrespect to loads “L1” and “L2”.

In light of the relative load sharing features of concrete walls andwalls of the invention, for a given building structure, the buildingload from that portion of the building which overlies the foundationwall, delivered through the foundation wall to the footer by a wall ofthe invention, designed to carry such load, has a load variation alongthe length of the footer, which is substantially less than the loadvariation delivered through a corresponding concrete foundation wallwhich is designed to carry such building overlying load. And in general,the load delivered to the footer generally varies by less than about 50percent, typically by less than 25 percent, along any one 10 foot lengthof the footer.

No dimensions are given in FIG. 24, either dimensions of the wall orcone angle magnitudes, because the performance of a specific walldepends on the exact specifications of that wall. Thus, FIG. 24 showsthe general tendencies of walls of the invention for a given buildingstructure relative to concrete walls designed to handle a similarbuilding structure.

Another advantage of wall structures of the invention is that, for agiven footer design, wall structures of the invention can carry greateroverlying loads, on the foundation wall, than concrete foundation walls.

For example, consider a standard concrete wall 8 inches (20.3 cm) thickand 9 feet (2.7 meters) high, which weighs about 1000 lbs per linealfoot (1488 kg per lineal meter), overlying a 2-foot (0.6 meter) widefooter, where soil load capacity is 3000 lbs per square foot (14,637 kgper square meter), Given the 2-foot (0.6 meter) wide footer, loadcapacity of the soil is 6000 lbs per lineal foot (8925 kg per linearmeter). Since the concrete wall weighs 1000 pounds per lineal foot (1488kg per lineal meter), the overlying building structure is limited to nomore than 5000 pounds per lineal foot (7438 kg per lineal meter).

By contrast, using the same parameters, but replacing the concrete wallat 1000 pounds per lineal foot (1488 kg per lineal meter) with wallstructure of the invention, which is about 25-60 pounds per lineal foot(37-89 kg per lineal meter), the overlying building structure can exertas much as at least 5911 pounds per lineal foot (8793 kg per linealmeter), an 18% increase in the amount of the load bearing capacity ofthe soil which can be derived from the building structure which overliesthe foundation wall.

Yet another advantage of walls of the invention is the fact thatvariation in the finished height of a foundation wall can be controlledmore closely in walls of the invention than can the finished height of afoundation wall be controlled where the wall is constructed on site frompoured ready-mix concrete or concrete block walls. Namely, even usinghighly skilled masons, a variation in height of a finished concrete wallof 0.5 inch (12.7 mm) to 1.0 inch (25.4 mm) is quite common. Suchvariations can be attributed at least in part by the fact that ready-mixforms are set by hand. Whatever the cause of such variations, such isthe experience in the industry.

Such variation generally transfers to overlying portions/floors of thebuilding structure, resulting in unintended structural dimensionvariations and load distribution variations.

By contrast, because wall panels and walls of the invention are bydefinition fabricated, at least as to height, in a fixed-locationmanufacturing facility, the height variation can be substantiallyattenuated, thus substantially attenuating such unintended structuraldimension variations and load distribution variations. Overall, wallpanels of the invention, when installed in buildings, can have heightvariations over a 40 foot (12.2 meter) length of the wall panel of lessthan 0.5 inch (12.7 mm), optionally no more than 0.25 inch (6.3 mm),optionally less than 0.13 inch (3.3 mm), and typically no more thanabout 0.063 inch (1.6 mm).

Among the requirements of the wall structure member is that thematerials in the wall structure cannot be sensitive to, susceptible tosubstantial degradation by, water or any inclusions commonly found inwater, whether dissolved minerals or organic materials such as lifeforms which live on or transform the compositions of the fibers. Namely,the materials cannot be susceptible to degradation by water or anythingin water, to the extent such degradation jeopardizes the ability of thestructure made from such building panels, to provide the compressivestrength necessary to support the overlying building loads, and thebending loads imposed by subterranean forces, and above-grade externalforces.

Accordingly, the wall elements typically do not include uncoatedcorrugated wood fiber structures commonly referred to as corrugatedcardboard structures, or any other fibers whose strengths aresubstantially affected by moisture or moisture vapor. Nor do the wallelements typically include any inclusions which are substantiallyaffected by materials which can be expected to exist in moisture foundin or around the soil adjacent a building structure. Further, fibers orother inclusions cannot be susceptible to insect infestation, or anyother degrading factors. Thus, fibers or other inclusions are generallyinorganic materials which are not deleteriously affected, namely whoseuseful properties are not severely degraded, by the environment in whichthe wall panels are used, over the expected use life of such wallpanels; which use life generally conforms to local industry standards.

While a pultrusion process has been described herein for making wallpanels of the invention, panels 14 can be made by other knownfabrication processes such as wet bag processes, and optionally baginfusion processes. Wet bag processes are especially beneficial withcertain ones of the panel configurations.

In any of the embodiments of the invention, one or more gel coats can beapplied to the panel structure at one or both of the inner and outersurfaces.

Whatever the materials used for the reinforcing fiber, the foam, theresin, all of such elements, including UV inhibitors, fire retardant,any fillers, any intumescent material, any smoke toxicity suppressant,any smoke generation suppressant, any wetting agent, any fluidityenhancers, or any other additives, are chemically and physicallycompatible with all other elements with which they will be in contact,such that no deleterious chemical or physical reaction takes placebetween cooperating materials which are used in fabricating wall systemsof the invention.

One of the substantial benefits of wall structures made using theteachings of the invention is that the wall structures are water-proofand moisture proof. For example, in areas where hurricanes are frequent,building codes require concrete structure in above-grade housing walls.Experience has shown that hurricane-force winds drive rain forcefullythrough such concrete wall structures so as to cause substantial waterdamage even when the building structure, itself, is not damaged.

By contrast, wall structures of the invention are essentially waterproof; and such water proof characteristic is not affected byhurricane-driven rain. Outer layer 36, 236 is, itself, water proof.While layer 36, 236 is quite tough for water to penetrate, even if outerlayer 36, 236 is breached, the foam 32 is water proof in that theindividual cells of the foam 32 are typically closed cells. If the foamlayer is also breached, inner layer 34 is also water proof. In anyevent, any breaching force has to penetrate multiple waterproof layers,at least two of which are substantially tough layers when considered inlight of the types of forces which are typically imposed on buildings byweather or other typical outside loads. The structures which do notinclude foam are substantially similarly-effective barriers to waterpenetration.

Regarding the joint between the bottom of the wall panel and the bottomplate, such joint can be filled with curable resin as discussed earlierherein, with adhesive, with caulk, or with other barrier material, thusto block any penetration of water at the joint between the wall paneland the bottom plate.

Similarly, vertical joints in the foundation wall can be closed to waterpenetration by applying curable resin, adhesive, caulk, or otherwater-proofing coatings to the joint, as well as using “H” brackets 140.In addition, as mentioned elsewhere herein, adhesives, resins, and thelike can be applied to the building panels and/or to the variousbrackets before the brackets are applied to the respective buildingpanels, thereby to provide further water-proofing characteristics to thefinished foundation wall, or above-grade wall.

Building panels of the invention find use in various residential, lightcommercial and industrial construction applications. The strength andother specifications of a given wall panel is specified in accord withthe loads to be imposed during the anticipated use life of the building.

Wall structures of the invention find application in and as, for exampleand without limitation, the construction of foundation walls; frostwalls e.g. in buildings which have no basement; manufactured home basecurtain walls; floor systems; ceiling systems, roof systems; exteriorabove-grade walls; curtain walls as in high rise construction replacingconcrete block; and exterior walls in areas that use masonry exteriors,such as in coastal construction. While the specification and drawingshave focused on foundation walls, the principles disclosed herein applyin the same way to other uses of panels and accessories of theinvention.

A variety of accessories and parts can be used with projects which usewalls of the invention, for example and without limitation, posts tosupport beams/girders, fiber-reinforced piers which optionally includestructural top and bottom, post pads, inside corner brackets, outsidecorner brackets, “H” channel brackets, top plate connectors, garagefloor shelves, support brackets, floor-and-garage apron brackets,service door cut outs, garage door cut outs, frost wall transitions, andstud profiles.

In addition, there can be mentioned fiber and resin patch kits suitablefor use to patch a damaged building panel, angled wall connectors, fullbasement wall to garage transition, frost wall returns, attachment oftop and bottom plates, along with potential shipping advantages wherethe top and bottom plates and/or other elements are affixed at theconstruction site, beam pockets, post pads in the footer to distributeload, and window bucks. There can also be mentioned fasteners to applyexterior product and to provide connections to other parts of thebuilding. Such fasteners can be, for example and without limitation,metal or fiber-reinforced polymer composite. A wide variety ofaccessories can be affixed to the wall structure using conventionallyavailable adhesives and/or mechanical fasteners such as screws andbolts, for field applications.

A specific advantage of wall systems of the invention is that such wallsystems can be readily sized and configured for use withalready-available standard size conventional building products, e.g.construction materials.

Building panels of the invention can be cut, using conventional toolscommonly available at a construction site, to fit the needs of the jobat hand. For example, a panel can be cut for length. A window openingcan be cut out. A door opening can be cut out. Utility perforations ofthe foundation wall can be cut, such as for furnace fresh air intake orcombustion gas exhaust, or the like, or such utilities can be run incavities 131 between studs 123 and inwardly of inner layer 34.

Advantages of the invention include, without limitation, a compositebottom plate which has potential to provide a wider footprint to theunderlying soil than the projected area of the wall panel, fordistributing the overlying weight of the building. The bottom plate canbe applied on site or off site. The wall structures of the invention arelight weight compared to the concrete structures they replace. The wallstructures of the invention are waterproof, versatile, mold resistant,termite resistant, and rot resistant. The substantial polymericcomponent of the compositions of wall structures of the inventionprovides a desired level of radon barrier in accord with existingbuilding codes whereby the conventionally-used polymeric layer on theoutside of the foundation wall is not needed, and can be omitted, alongwith corresponding savings in material and labor costs.

Typical wall structures of the invention can be installed with onlyminimal equipment or manual labor, and do not require bringing any largemachines to the construction site for the purpose of installing afooter, a foundation wall, or an above-grade wall, no ready-mix truck,no form truck, and only a light-duty crane to install the buildingpanels.

The invention does contemplate larger wall panels, e.g. thicker, taller,and/or longer, which can weigh at least 200-800 pounds (363-907 kg) ormore. Further, where a wall or roof panel is being erected above theground floor, a suitable-weight light-duty crane, such as for liftinge.g. up to about 3500 pounds (1587 kg) facilitates such greater-heightinstallation.

Wall structures of the invention can be installed in all seasons and allweather, so long as the excavation can be dug to a suitable naturalsupport base. Panels of the invention are environmentally friendly.Panels of the invention are consistent with the requirements to qualifyas Green buildings and/or as Energy Star buildings whereby buildingsbuilt with building panels of the invention may qualify for suchratings. No damp proofing is needed. Once the foundation walls are inplace, the interior of the so-enclosed space is ready to be finished.HVAC cavities are available between studs 123 as e.g. in spacings 131.Plumbing and electric can also be run through the walls easily becausethe walls are easily drilled or cut at the construction site, againbetween studs 123, optionally inside studs 123.

The building panels can be repaired more readily than concrete. Openingscan be cut more easily than concrete. Wall changes can be made moreeasily than concrete. Any typical wall height can be achieved with afacile cutting process. The building panels can be installed on anaggregate stone footer, whereby no pouring of a concrete footer isrequired. Thus, the lowest level wall of the building can be completedwith no need for any ready-mix concrete at the construction site.

Wall structures of the invention have multiple desirable properties,including being fire resistant where fire retardant ingredients areincluded in the resin formulation, or when intumescent material is usedin layer 34, being a good barrier to ultraviolet rays, providing goodsound attenuation, being generally free from insect infestation, beinggenerally not susceptible to infestation by rot-generating organisms,being a good barrier to water, including being a good barrier to drivenrain, and being a good barrier to transmission of radon gas.

Wall structures of the invention are sturdy, durable, and have veryfavorable expansion and contraction ratings compared to the concretethey replace. The wall structures tolerate a wide range of temperaturessuch as are encountered in building construction. The building panels ofthe invention are easy to transport to the construction site. Thebuilding panels can be mass-produced and do not have to beproject-specific like known e.g. insulated wall systems which areproduced off-site, and transported to the construction site aspre-fabricated wall systems. Wall, ceiling, roof, and floor structuresof the invention can be installed in locations where it is difficult toget delivery of ready-mix concrete, such as on islands, in weightrestricted areas, in high-rise curtain walls, and the like.

Although the invention has been described with respect to variousembodiments, it should be realized this invention is also capable of awide variety of further and other embodiments within the spirit andscope of the appended claims. Thus, wall panels and walls of theinvention can be used for a variety of implementations, which maysuggest thicker walls, or stronger walls, in order to achieveperformance requirements of the walls. Other implementations may suggestthinner walls, or weaker walls, for cost-effectiveness. Such walls mayor may not include studs 123, intercostals 50, 250, or “T's” 46. Inlight of the invention as disclosed herein, those skilled in theconstruction arts are now enabled to design such walls according to theneeds of their particular building projects. All such otherimplementations are contemplated herein.

Those skilled in the art will now see that certain modifications can bemade to the apparatus and methods herein disclosed with respect to theillustrated embodiments, without departing from the spirit of theinstant invention. And while the invention has been described above withrespect to the preferred embodiments, it will be understood that theinvention is adapted to numerous rearrangements, modifications, andalterations, and all such arrangements, modifications, and alterationsare intended to be within the scope of the appended claims.

To the extent the following claims use means plus function language, itis not meant to include there, or in the instant specification, anythingnot structurally equivalent to what is shown in the embodimentsdisclosed in the specification.

1. A method of fabricating a fiber reinforced polymeric wall panel,comprising: (a) feeding to a pultrusion apparatus a fiber schedule and aresin composition; (b) generally continuously pultruding and setting,from such fiber schedule and resin composition, a fiber reinforcedpolymeric wall panel profile comprising an inner layer, an outer layer,and spaced reinforcing webs extending between the inner and outerlayers, a male edge, and a female edge; (c) cutting the pultruded wallpanel periodically for wall panel height dimension, to thereby create anongoing stream of cut wall panels wherein the studs extend along suchheight dimensions of such cut wall panels; (d) advancing the cut wallpanels to an index station; (e) indexing the wall panels in a generallyright angle direction while maintaining the orientation of the wallpanels, such that adjacent wall panels leave the indexing station inadjacent male-to-female edge-to-edge relationship; (f) applying abonding material to the facing edges of adjacent ones of the wallpanels; and (g) joining the male/female structures of the adjacent wallpanel edges, through the bonding material so as to join the respectivewall panels together in a combined wall panel
 2. A method as in claim 1,further comprising feeding elongate blocks of foam to the pultrusionapparatus such that the blocks of foam are fully embedded in theresulting pultrusion product.
 3. A method as in claim 1, furthercomprising feeding to the pultrusion apparatus, an intumescent materialwhich is disposed at or adjacent the inner layer in the resultantpultruded profile.
 4. A method as in claim 1, further comprisingforming, in the pultrusion apparatus, as part of the wall panel profile,a plurality of studs spaced from each other and extending parallel toeach other and along the direction of pultrusion of the wall panelprofile, and extending, from the inner layer, away from the outer layera distance of at least about 1 inch (2.5 cm).
 5. A method of fabricatinga fiber reinforced polymeric wall panel, comprising: (a) feeding to apultrusion apparatus a fiber schedule, a resin composition and one ormore elongate blocks of thermally insulating foam; and (b) generallycontinuously pultruding and setting, from such fiber schedule and resincomposition, a fiber reinforced polymeric wall panel profile comprisingthe foam blocks, an inner layer, an outer layer, and spaced reinforcingwebs extending between the inner and outer layers, the foam blocks beingenclosed between the inner layer, the outer layer, and the spacedreinforcing webs.
 6. A method as in claim 5, further comprising forming,in the pultrusion apparatus, as part of the wall panel profile, aplurality of studs spaced from each other and extending parallel to eachother and along the direction of pultrusion of the wall panel profile,and extending, from the inner layer, away from the outer layer adistance of at least about 1 inch (2.5 cm).
 7. A method as in claim 5,further comprising feeding to the pultrusion apparatus, an intumescentmaterial which is disposed at or adjacent the inner layer in theresultant pultruded profile.
 8. A method of fabricating a fiberreinforced polymeric wall panel, comprising: (a) feeding to a pultrusionapparatus a fiber schedule and a resin composition; and (b) generallycontinuously pultruding and setting, from such fiber schedule and resincomposition, a fiber reinforced polymeric wall panel profile comprisinga fiber-reinforced polymeric inner layer, a fiber-reinforced polymericouter layer, spaced fiber-reinforced polymeric reinforcing websextending between the inner and outer layers, and a plurality of studsspaced from each other and extending parallel to each other and alongthe direction of pultrusion of the wall panel profile, and extending,from the inner layer, away from the outer layer a distance of at leastabout 1 inch (2.5 cm).
 9. A method as in claim 8, further comprisingfeeding elongate blocks of foam to the pultrusion apparatus such thatthe blocks of foam are fully embedded in the resulting pultrusionproduct.
 10. A method as in claim 8, further comprising feeding to thepultrusion apparatus, an intumescent material which is disposed at oradjacent the inner layer in the resultant pultruded profile.
 11. Afiber-reinforced polymeric structural building panel, designed andadapted to be used in constructing a building, said building panelhaving a height extending between a top and a bottom of said buildingpanel, a length, and a thickness, all defined when said building panelis in an upright use orientation, said structural building panelcomprising: (a) a first outer fiber-reinforced structural polymericlayer; (b) a second inner fiber-reinforced structural polymeric layerspaced from said first layer by a first distance; (c) one or morestructurally reinforcing webs, spaced from each other, and extendingfrom said first fiber-reinforced polymeric layer to said secondfiber-reinforced polymeric layer; and (d) a plurality of structurallyreinforcing fiber-reinforced polymeric studs spaced from each otheralong the length of said building panel and extending inwardly from saidinner layer, away from said outer layers said studs extending from saidinner layer to end panels (130) of said studs, said building panel, whenincorporated into a building and being subjected to an overlyingbuilding load, evenly distributed between said outer layer and said endpanels, deflecting between the top and bottom of said panel in adirection toward said outer layer.
 12. A fiber-reinforced polymericstructural building panel as in claim 11, deflection of said buildingpanel under rated load being limited to no more thanDeflection=L/240, where L is the top-to-bottom height of the buildingpanel, and deflection and “L” are expressed in a common unit of measure.13. A fiber-reinforced polymeric structural building panel as in claim11, said studs extending inwardly from said inner layer, and away fromsaid outer layer, a distance greater than the first distance.
 14. Astructural outer wall in a building, comprising an uprightfiber-reinforced polymeric structural building panel, said buildingpanel overlying a footer, said building panel having a height extendingbetween a top and a bottom of said building panel, a length, and athickness, said structural building panel comprising: (a) a first outerfiber-reinforced structural polymeric layer; (b) a second innerfiber-reinforced structural polymeric layer spaced from said first layerby a first distance; and (c) one or more structurally reinforcing webs,spaced from each other, and extending from said first fiber-reinforcedpolymeric layer to said second fiber-reinforced polymeric layer saidstructural building panel being subjected to an overlying building load,and delivering such overlying building load to the footer such that thedelivered load generally varies by less than about 50 percent along anyone 10 foot length of the footer.
 15. A structural outer wall in abuilding as in claim 14, said first and second layers being spaced fromeach other by a first distance, said wall panel further comprising aplurality of structurally reinforcing studs spaced from each other alongthe length of said building panel and extending inwardly from said innerlayer, away from said outer layer, a second distance greater than thefirst distance.
 16. A structural outer wall in a building as in claim 14wherein the wall panel is subjected to an overlying building load, andwherein said wall panel deflects, between the top and bottom of the wallpanel, toward said outer layer.
 17. A structural outer wall in abuilding as in claim 14 wherein the deflection is limited to no morethanDeflection=L/240, where L is the top-to-bottom height of the buildingpanel, and deflection and “L” are expressed in a common unit of measure.18. A fiber-reinforced polymeric structural building panel, designed andadapted to be used in constructing a building, said building panelhaving a height extending between a top and a bottom of said buildingpanel, a length, and a thickness, all defined when said building panelis in an upright use orientation, said structural building panelcomprising: (a) a first outer fiber-reinforced structural polymericlayer; (b) a second inner fiber-reinforced structural polymeric layerspaced from said first layer by a first distance; (c) one or morestructurally reinforcing webs, spaced from each other, and extendingfrom said first fiber-reinforced polymeric layer to said secondfiber-reinforced polymeric layer; and (d) a plurality of structurallyreinforcing fiber-reinforced polymeric studs spaced from each otheralong the length of said building panel, each said stud comprising firstand second legs (128) extending inwardly from said inner layer, awayfrom said outer layer, to an end panel (130), a said one of said legs(128) being aligned with one of said structurally reinforcing webs. 19.A fiber-reinforced polymeric structural building panel as in claim 18,deflection of said building panel under rated load being limited to nomore thanDeflection=L/240, where L is the top-to-bottom height of the buildingpanel, and deflection and “L” are expressed in a common unit of measure.20. A fiber-reinforced polymeric structural building panel as in claim18, said studs extending inwardly from said inner layer, and away fromsaid outer layer, a distance greater than the first distance.
 21. Afiber-reinforced polymeric structural building panel as in claim 18wherein, when said building panel is subjected to an overlying buildingload, said building panel deflects, between the top and bottom of thebuilding panel, toward said outer layer.
 22. A fiber-reinforcedpolymeric structural building panel, designed and adapted to be used inconstructing a building, said building panel having a height extendingbetween a top and a bottom of said building panel, a length, and athickness, all defined when said building panel is in an upright useorientation, said structural building panel comprising: (a) a firstouter fiber-reinforced structural polymeric layer comprising first andsecond uprightly oriented layers of unidirectional fiberglass rovings,and a surface veil, collectively in combination with a resincomposition; (b) a second inner fiber-reinforced structural polymericlayer spaced from said first layer by a first distance and comprisingthird and fourth uprightly oriented layers of unidirectional fiberglassrovings, and an intumescent veil, collectively in combination with saidresin composition; (c) a plurality of structurally reinforcing webs,spaced from each other, and extending from said first fiber-reinforcedpolymeric layer to said second fiber-reinforced polymeric layer, saidreinforcing webs comprising fiberglass rovings arranged between saidinner and outer layers, collectively in combination with said resincomposition, said first and second fiber-reinforced structural polymericlayers, in combination with said reinforcing webs, defining spacestherebetween at each occurrence of the respective reinforcing webs; and(d) a plurality of structurally reinforcing fiber-reinforced polymericstuds spaced from each other along the length of said building panel,each said stud comprising first and second legs (128) extending inwardlyfrom said inner layer, away from said outer layer, to an end panel(130), said third layer of uprightly oriented unidirectional fiberglassrovings extending between said reinforcing web rovings and said studs,said fourth layer of uprightly oriented unidirectional fiberglassrovings extending about said studs at said legs and said end panels, afifth layer of fiberglass rovings being disposed inwardly in each ofsaid studs from said fourth layer of uprightly oriented unidirectionalfiberglass rovings, in combination with said resin composition.
 23. Afiber-reinforced polymeric structural building panel as in claim 22,further comprising blocks of foam filling the spaces between thereinforcing webs and the inner and outer layers.
 24. A fiber-reinforcedpolymeric structural building panel as in claim 22 wherein the blocks offoam are integrally connected with the combination of fiberglass layersand resin composition in the inner and outer layers and in thestructurally reinforcing webs.
 25. A fiber-reinforced polymericstructural building panel as in claim 22, a said one of said legs (128)being aligned with one of said structurally reinforcing webs.
 26. Afiber-reinforced polymeric structural building panel as in claim 22wherein each of said first, second, third, and fourth layers offiberglass rovings is accompanied by an adjacent chopped strand matlayer.
 27. A fiber-reinforced polymeric structural building panel as inclaim 26 wherein the chopped strand mat layers accompanying each of thefirst and second layers of fiberglass rovings is between the respectiverovings and the surface veil, and wherein the chopped strand mat layersaccompanying each of the third and fourth layers of fiberglass rovingsis between the respective rovings and the intumescent veil.
 28. Afiber-reinforced polymeric structural building panel as in claim 27,further comprising blocks of foam filling the spaces between thereinforcing webs and the inner and outer layers.
 29. A structural outerwall in a building, comprising an upright fiber-reinforced polymericstructural building panel, said building panel overlying a footer, saidbuilding panel having a height extending between a top and a bottom ofsaid building panel, a length, and a thickness, said structural buildingpanel comprising: (a) a first outer fiber-reinforced structuralpolymeric layer; (b) a second inner fiber-reinforced structuralpolymeric layer spaced from said first layer by a first distance,whereby one or more spaces exist between said inner and outer layers;and (c) at least one of (i) one or more structurally reinforcing webs,spaced from each other, and extending between said inner layer and saidouter layer, and (ii) one or more foam boards filling the one or morespaces between said inner and outer layers; said structural buildingpanel, having a height variation corresponding to a height variationover a 40 foot length of said building panel, at the top of saidbuilding panel, of no more than about 0.25 inch.
 30. A structural outerwall as in claim 29, said structural building panel, having a heightvariation corresponding to a height variation over a 40 foot length ofsaid building panel, at the top of said building panel, of no more thanabout 0.13 inch.
 31. A structural outer wall as in claim 29, saidbuilding panel further comprising a plurality of structurallyreinforcing fiber-reinforced polymeric studs spaced from each otheralong the length of said building panel and extending inwardly from saidinner layer, away from said outer layer by a distance of at least 1inch.
 32. A structural outer wall in a building, comprising an uprightfiber-reinforced polymeric structural building panel, said buildingpanel overlying a footer, said building panel having a height extendingbetween a top and a bottom of said building panel, a length, and athickness, said structural building panel comprising: (a) a first outerfiber-reinforced structural polymeric layer; (b) a second innerfiber-reinforced structural polymeric layer spaced from said first layerby a first distance, whereby one or more spaces exist between said innerand outer layers; and (c) at least one of (i) one or more structurallyreinforcing webs, spaced from each other, and extending between saidinner layer and said outer layer, and (ii) one or more foam boardsfilling the one or more spaces between said inner and outer layers; saidstructural building panel, being generally free from substantial rackingor crumbling in response to external forces from outside the building,such as seismic activity.